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Vibration Analysis

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Vibration analysis is a non-destructive technique to detect machine problems by measuring vibration. Key sources of vibration include unbalance, misalignment, bearing defects, and gear/blade issues. Vibration can be measured through displacement, velocity, and acceleration.

Vibration analysis is a technique which helps early detection of machine problems by measuring vibration in order to identify issues like unbalance, misalignment, looseness, and defects.

Common sources of vibration include unbalance, misalignment, eccentricity, looseness, resonance, and bearing/gear/blade defects.

What Is Vibration?

It is the response of a
system to an internal or
external force which causes
the system to oscillate.

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What Is Vibration Analysis?


Vibration analysis
is a non-destructive
technique which
helps early
detection of machine
problems by
measuring vibration.

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Detection By Vibration Analysis


1. Unbalance(Static, Couple, Quasi-Static),
2. Misalignment(Angular, Parallel, Combination)
3. Eccentric Rotor, Bent Shaft
4. Mechanical Looseness, Structural Weakness, Soft Foot
5. Resonance, Beat Vibration
6. Mechanical Rubbing
7. Problems Of Belt Driven Machines
8. Journal Bearing Defects
9. Antifriction Bearing Defects
(Inner race, Outer race, Cage, Rolling Elements)
10.Problems of Hydrodynamic & Aerodynamic Machines
(Blade Or Vane, Flow turbulence, Cavitation)
11.Gear Problems (Tooth wear, Tooth load, Gear eccentricity,
Backlash, Gear misalignment, Cracked Or Broken Tooth)
12.Electrical Problems of AC & DC Motor ( Variable Air Gap,
Rotor Bar Defect, Problems of SCRs)

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Basic Theory Of Vibration


Simple Spring Mass System

Neutral
Position
Lower
Position

Max Vel
Mim Acc

Displacement

Upper
Limit

Max Acc
Mim Vel

Max Acc
Mim Vel

It follows sine curve.

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Frequency & Amplitude


Frequency:
How many times oscillation is occurring
for a given time period?

Units: CPS(Hz), CPM

Amplitude:
It is the magnitude of vibration signal.
Units: Micron, MM/Sec, M/Sec2

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Physical Significance Of
Vibration Characteristics
Frequency

- What is vibrating?
Source of the vibration.

Amplitude

- How much is it vibrating?


Size (severity) of the problem.

Phase Angle - How

is it vibrating?
Cause of the vibration.

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Frequency Measurement

60 RPM
= 1 Rev / s
= 1 Hz

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Amplitude Measurement
1. Displacement :
Total distance traveled by the mass.
Unit : Microns

2. Velocity

Rate of change of displacement. It is the


measure of the speed at which the mass is
vibrating during its oscillation.
Unit : MM/Sec, Inch/sec

3. Acceleration :
It is the rate of change of velocity. The
greater the rate of change of velocity the
greater the forces (P=mf) on the machines.
Unit : M/Sec2, Inch/sec2
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A
B
C

a
t

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+
a

v
t

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Physical Significance Of Vibration


Amplitude
Displacement :

Stress

Velocity

Fatigue Indicator

Acceleration :

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Force

Indicator

Indicator

11

When To Use Disp., Vel. & Acc.?


VIBRATION
SENSITIVITY

DISPLACEMENT

10

.1

VELOCITY

.01

.001

ACCELERATION

60

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600

6000

60000

600 000 FREQUENCY


CPM
12

What Is The Advantage Of Using


Velocity?
Flat frequency range compared to
displacement & acceleration.
Almost all machines generate fault
frequency between 600CPM to 60KCPM
Velocity indicates fatigue.
Velocity is the best indicator of
vibration severity.

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Peak
Peak to Peak
RMS
Average
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Peak to Peak

Peak

RMS

Av.

Scales Of Amplitude

a
2a
0.707 a
0.637 a
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Vibration Transducers
Produces electrical signal of vibratory motion

Proximity Probe - Displacement


Velocity Probe
- Velocity
Accelerometer - Acceleration

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Proximity Probe

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Permanently installed on large machines


Measures relative displacement between the bearing
housing and the shaft.
Called Eddy Current Probe
Frequency range 0 to 60,000 CPM
Used 900 apart to display shaft orbit

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Velocity Probe

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Oldest of all.
Produces signal proportional to velocity.
Self generating and needs no conditioning electronics.
It is heavy, complex and expensive.
Frequency response from 600CPM to 60,000CPM
Temperature sensitive
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Accelerometer

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Produces signal proportional to


acceleration of seismic mass.
Extremely linear amplitude sense.
Large Frequency range
Smaller in size
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Phase
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What Is Phase?
Phase is a measure of relative time difference between two sine waves.

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Importance Of Phase

Phase is a relative measurement.


Provides information how one part of a machine is vibrating
compared to other.
Confirmatory tool for problems like1. Unbalance(Static, Couple, Quasi-Static).
2. Misalignment(Angular, Parallel, Combination).
3. Eccentric Rotor, Bent Shaft.
4. Mechanical Looseness, Structural Weakness, Soft Foot.
5. Resonance.
6. Cocked bearing.

No correlation with Bearing defects, Gear defects,


Electrical motor defect.

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How Phase Angle Is Measured?


The Phase Angle is the angle (in degrees) the
shaft travels from the start of data collection to
when the sensor experiences maximum positive
force.
For example, the phase angle is 90 if the sensor
experiences its maximum positive force at 90
after data collection was initiated by the
tachometer.
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Step - 1

The tachometer senses the notch in the shaft and triggers data collection.
At this point force equals zero.

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Step - 2

The high spot (heavy spot) rotates 90 to the sensor position.


At this point the unbalance force produces the highest positive
reading from the sensor.

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Step - 3

The high spot rotates 90 additional degrees,


the force experience by the sensor is again zero.

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Step - 4

The high spot rotates 90 additional degrees opposite the sensor position.
At this point the unbalance force produces the highest negative reading
from the sensor.

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Step - 5

The high spot rotates 90 additional degrees to complete its 360


revolution, the force experienced by the sensor is again zero.

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Phase Angle
During the 3600 shaft rotation, the sensor
experiences its maximum positive force
when the shafts heavy spot is 900 from
its initial position when data collection was
initiated by the tachometer.
This measurements phase angel = 90

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FFT
Spectrum
Analysis
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What Is FFT?
Known as Fast Fourier Transformation.
Developed by J.B. Fourier in 1874.

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FFT mathematically converts overall complex


signal into individual amplitudes at component
frequencies

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Different machinery problems cause


vibration at different frequencies.
Overall vibration coming out from machine
is combination of many vibration signals
form various machine parts and its
structure.
FFT is a method of viewing the signal with
respect to frequency.

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Pure sinus

CPM

CPM

2 sine waves

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Pure sinus
0.900984

1.41421

-1.41421
0

100

1.06721e-008

CPM

3 sine waves
1

1.17033e-008

CPM

Complex motion
3.75895

14.1221

-14.7102
0

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200

0.00679134

CPM
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Spectrum
Analysis
Techniques
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Step - 1
Collect useful information
History of machine.
Control room data - speed, feed,
temperature, pressure etc.
Name plate details - bearing no,
no of gear teeth etc.
Design operating parameters,
critical speed.

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Step - 2 : Identify the type of


measurement procedure:
1. Identify measurement type-Disp, Vel, Acc.

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Conversion Of Spectrums
Displacement
Displacement- Microns
- Microns
Speed - 2889 RPM

Velocity - mm/s

Acceleration - m/s2

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2. Measurement direction - Hori, Vert, Axial.

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Step - 3
Analyze:
1. Evaluate overall vibration reading of the entire
machine.
(a) Identify 1x RPM peak.
(b) Locate highest amplitude.
(c) What is the direction of the highest amplitude?
(d) What is the frequency of the highest amplitude?
2. See the values of Shock pulse, HFD etc.
3. See the trend - in case of sudden increase the
problem severity increases.
4. Analyze the frequency for possible defects.
5. Analyze the phase readings for confirmation if
necessary.

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Manual
Vibration
Analysis
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Detection By Vibration Analysis


1.
2.
3.
4.
5.
6.
7.
8.
9.

Unbalance(Static, Couple, Quasi-Static),


Misalignment(Angular, Parallel, Combination)
Eccentric Rotor, Bent Shaft
Mechanical Looseness, Structural Weakness, Soft Foot
Resonance, Beat Vibration
Mechanical Rubbing
Problems Of Belt Driven Machines
Journal Bearing Defects
Antifriction Bearing Defects
(Inner race, Outer race, Cage, Rolling Elements)
10.Hydrodynamic & Aerodynamic Forces
(Blade Or Vane, Flow turbulence, Cavitation)
11.Gear Problems (Tooth wear, Tooth load, Gear eccentricity,
Backlash, Gear misalignment, Cracked Or Broken Tooth)
12.Electrical Problems of AC & DC Motor ( Variable Air Gap,
Rotor Bar Defect, Problems of SCRs)

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Unbalance
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Causes Of Unbalance

Uneven distribution of mass of rotor.


Dirt accumulation on fan rotors.
Rotor eccentricity
Roller deflection, especially in paper machines
Machining errors
Uneven erosion and corrosion of pump impellers
Missing balance weights

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Types Of Unbalance

Static Unbalance
Couple Unbalance
Overhang Rotor Unbalance

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Static Unbalance

Detection:

Highest horizontal vibration


Amplitude increases as square of speed.
Dominant frequency at 1x rpm
Horizontal to vertical phase difference 900 on
the same bearing housing
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Correction

Can be corrected by one balance weight

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2. Vibration Phase Analysis:


Angular

- 1800 phase shift in the axial direction


across the coupling.

Offset

- 1800 phase shift in the radial direction


across the coupling. 00 to 1800 phase shift
occur as the sensor moves from horizontal to
the vertical direction of the same machine.

Skew

- 1800 phase shift in the axial or radial


direction
across the coupling.

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Couple Unbalance

Detection:
High horizontal & some times axial vibration
Dominant frequency at 1x RPM
1800 phase difference between both bearings
horizontal as well as vertical direction.

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Correction

It requires two plane balancing

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Overhung Rotor Unbalance

Detection:
High horizontal & axial vibration
Dominant frequency at 1x RPM
Axial readings will be in phase but radial
phase readings might be unsteady.

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Correction
Overhung rotors might be having both
static and couple unbalance and each of
which requires correction.

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Misalignment
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Causes Of Misalignment
Thermal

expansion

- Most

machines

align

cold.

Machine vibrations.
Forces transmitted to the machine by pipe or
support structure.
Soft foot.
Direct coupled machined are not properly aligned.
Poor workmanship.

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Types Of Misalignment
1. Off set

2. Angular

3. Skew - Combination of
offset & angular
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Diagnosis Of
Misalignment
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1.Vibration Spectrum Analysis:

Angular

- Axial vibration at

Offset

- Radial vibration at 2X or 3X RPM

1X RPM

Harmonics (3X-10X) generates as severity increases.


If the 2X amplitude more than 50% of 1X then
coupling damage starts.
If the 2X amplitude more than 150% of 1X then
machine should be stopped for correction.
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Misaligned Or Cocked Bearing

1. Predominant 1X & 2X in the axial direction.


2. 1800 Phase shift top to bettom and/or side to
side of the axial direction of the same bearing
housing.

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Bent Shaft

Diagnosis:
1. High 1X axial and high 1X radial if bent is near the center.
2. High 2X axial and high 2X radial if bent is near the coupling.
3. The phase of the 1X component 1800 at opposite ends of rotor.
4. Phase difference of 1800 between left & right hand side and
also upper & lower sides of the same bearing housing in the
axial direction.
5. Amplitude of 1X & 2X rpm will be steady.
6. High bearing temperature.

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Eccentric Rotor

When center of rotation is offset from geometric center.


Dominant frequency 1X.
Horizontal to Vertical phase difference either 00 or 1800
at the same bearing housing (Both indicate straight-line
motion).

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Resonance
Occurs when forcing frequency coincides
with system natural frequency.
Causes amplitude amplification which
results catastrophic failure.
Requires changing of natural frequency
or change of operating speed.
Bode plot is used to identify resonance.

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Beat Vibration
It is the result of two closely spaced frequencies
going into and out of synchronization with one
another.
The spectrum will show one peak pulsating up
and down.
Low frequency vibration 5 to 100 CPM.
Beat frequencies are not normally a problem
when the differences exceed 150 to 200 CPM.

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Mechanical
Looseness
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Causes
It alone can not create vibration but in
the influence of Unbalance,
Misalignment, Bearing problems it
amplify the amplitude.
It should be corrected first.

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Types
1. Structural frame/base looseness (1X)
2. Cracked structure/bearing pedestal (2X)
3. Rotating looseness - Loose bearing/improper
fit between component parts. (Multiple)

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1. Structural frame/base looseness (1X)


Caused by1. Structural looseness/weakness of machine feet,
baseplate & concrete base.
2. Deteriorated grouting.
3. Deterioration of frame or base
4. Soft foot.
5. Loose holding down bolts.

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Analysis
Dominant freq 1X. Similar to
unbalance & misalignment.
Horizontal to vertical phase diff 00 or
1800 at the same bearing housing.
1800 phase diff in the vertical direction
between two surfaces.

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2. Cracked structure/bearing pedestal (2X)


Caused by1. Crack in the structure or bearing pedestal.
2. Occasionally on some loose bearing housing bolts.
3. Loose bearing or improper component fit.

Analysis1. 2X RPM amplitude is > 150% of 1X RPM amplitude in


radial direction.
2. Amplitudes are somewhat erratic.
3. 2X RPM phase somewhat erratic.
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3. Rotating looseness
Caused by1. Loose rotor.
2. Bearing loose in the housing.
3. Bearing loose in the shaft.
4. Excessive bearing internal clearance.

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Analysis
1. Generates running speed harmonics up to 20X RPM.
2. Generates low amplitude frequencies of 1/2x (i.e. .5x, 1.5x, 2.5x)
and 1/3 x also.
3. Presence of 1/2x will indicate more advanced looseness problems
like presence of rub. It indicate other problems like unbalance and
misalignment.
4. Phase measurement will be erratic.
5. Phase for loose rotor will vary from one measurement to next.
6. Bearing loose on the shaft will generate 1x

RPM peak.
7. Bearing loose in the housing will generate 4x RPM peak.

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Journal
Bearing
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Oil Whirl

Cause: Excessive clearance and light radial loading.


This results in the oil film building up and forcing the
journal to migrate around in the bearing at less than
one-half RPM.
Oil whirl is a serious condition and needs to be corrected.
It can create metal to metal contact.

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A symptom peculiar for journal bearings is oil whirl.


It shows up as a vibration of approx. 0.42-0.48 X RPM.
Oil whirl can be diagnosed by increasing the load which
will decrease the subsyncronous vibration.

0.45X

mm/s rms

severe oil whirl will cause looseness

1X
2X
frequency

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Journal Looseness
(Rotating Looseness)

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Rotor Rub

Spectra similar to mechanical looseness.


It may be partial or full annular rub.
Often excites one or more resonances.
It can excites high frequencies.
Cascade diagram and shaft orbit are very
helpful in diagnosing rubs.

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Rolling
Element
Bearing
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Why Does Bearing Fail?


1. Improper lubrication
2. Contaminated lubrication
3. Heavier loading from unbalance,
misalignment, bent shaft etc.
4. Improper handling or installation.
5. Old age (Surface fatigue) .

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Bearing Failure Detection

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Bearing Failure Stages


Stage - 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.

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Stage - 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.

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Stage - 3

Bearing defect frequencies and harmonics appear.


More defect frequencies appear and nos of sidebands grow, both around these
and bearing natural frequencies.
When well-formed sidebands accompany bearing defect frequency harmonics
Bearing has to be replaced.

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Stage - 4

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.

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Rolling element bearings


FTF = Fundamental Train Frequency
BSF = Ball Spin Frequency
BPFO = Ball Pass Frequency Outer race
BPFI = Ball Pass Frequency Inner race

FTF

1.
2

BSF

BPFO

BPFI

d.

cos F . RPM

RPM = Shaft rotation

D .
1
2. d

d.

cos F

N. FTF

N. ( RPM - FTF)

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. RPM

d = Rolling element diameter


D = Pitch diameter
N = No. of rolling elements

F=

Contact angle

87

Rolling element bearings


What do the bearing frequencies mean?
If:
FTF = 0.381 * RPM
BSF = 1.981 * RPM
BPFO = 3.047 * RPM
BPFI = 4.952 * RPM

During one shaft revolution:


The cage rotates 0.381 revolutions
The ball spins 1.981 revolutions
4.952 balls pass an inner race defect
3.047 balls pass an outer race defect

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Gear Box
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Gear box
Z1
RPM1

RPM2
Z2

GMF (Gear Mesh Frequency)


Z1 .RPM1 = Z2 .RPM2
where Z = no. of teeth and RPM shaft speed
Mating gears produce only one Gear Mesh Frequency

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Gear Box Defects

Tooth wear
Gear eccentricity & backlash
Gear misalignment
Cracked or broken tooth
Hunting tooth

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Gear box
1/Rps
Z.Rps-Rps
Z.Rps-2 Rps

frequency

Z.Rps+Rps
Z.Rps+2 Rps

velocity

velocity

Z.Rps

time

Spur gear produce vibration in radial direction and


helical gear produce in radial & axial directions.
Sideband spacing reveals the defective gear or pinion.
All analysis should be done at maximum load.

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Normal Spectrum

All peaks are of low amplitudes


No natural frequency of gear excited
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Tooth Wear

GMF may not change


High amplitudes of side bands
Presence of natural frequency of gear (fn)

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Gear Eccentricity & Backlash

Excites GMF, fn & their side bands


High amplitudes of side bands
Sideband spacing reveals the defective
gear or pinion.
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Gear Misalignment

Excites harmonics of GMF with side bands


Amplitudes 2GMF or 3GMF higher than 1GMF

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Cracked / Broken Tooth

High amplitudes of 1x RPM of gear or pinion


Excites gear natural frequency.
Time waveform indicates spikes at 1/RPM of broken or cracked tooth.
Amplitudes of impact spikes in time waveform will be higher than
that of 1xRPM in FFT.

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Hunting Tooth
1. Faults on both gear & pinion occured
during manufacturing.
2. Causes high vibration at low
frequencies (less than 600CPM)
3. Gear set emits growling sound.

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Hunting Tooth Frequency


It is the rate at which a tooth in one gear mates with a particular
tooth in the other gear.
For well designed gearboxes HTF is low.

HTF = GMF . (lowest common prime factor) /(Z1.Z2)


Ex:
Z1 = 63, Z2 = 12
Z1 = 63 = 7.3.3
Z2 = 12 = 3.2.2
lowest common prime factor = 3
HTF = GMF. 3 / (63.12) = GMF / 252

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Belt Drive
d

BF (Belt Frequency) = Rps. .D / L


BF is the rotational frequency of the belt. Worn or mismatched belts will
produce radial vibration at BF and its harmonics. 2.BF is often dominant
with 2 sheaves in the system. BF is a subsyncronous vibration (below 1X).
( D d )2
L 2C 157
. (D d)
4C

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Belt Drive

Eccentric sheaves
force

Eccentric sheaves will generate strong 1X radial components.


A common condition.
Looks like unbalance, but shows at both sheaves.

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Belt Drive

Off-set

Sheave misalignment

Angular

Axial vibrations at 1X and BF with harmonics.

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Fans
Fan Blade Pass Frequency = RPM x no. of fan blades
(FBPF)
Mainly radial vibrations
FBPF with 1X RPM sidebands.
Unbalanced horizontal or axial vibrations.
Inadequate blade clearance (at FBPF or RPM harmonics)
Uneven velocity distribution across fan inlet gives FBPF vibrations

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Pumps
Vibration signature depends upon operating condition.
pressure, temperature, speed, cavitation.
Centrifugal pumps
at Vane Pass Frequency = RPM . no. of impeller vanes
and harmonics.
Gear pumps
at Gear Mesh Frequency and 1X sidebands
Screw pumps
at thread rate = RPM . number of threads and its
harmonics.
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Electrical
Motors
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AC Motors
Asyncronous AC motors
Running speed:
RPM sync

120

f
p

where p = number of poles


f = line frequency

If no. of poles = 2.
The motor will have a sync. RPM of 3000
fs = RPMsync - RPM

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where fs = slip frequency

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AC Motors
All electrical machines vibrates at 2 . line frequency.
The reasons are expanding and collapsing magnetic fields.
This vibration is normal (to a degree).
The amplitude is a measure of the quality of the construction.

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AC Motors
Coast Down Test

Vibration suddenly drops down after switching off the power

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AC Motors
Faults possible to detect with vibration analysis:
Rotor thermal bow
Air gap eccentricity
Loose rotor
Eccentric rotor
Loose windings
Necessary data:
No. of stator slots
No. of rotor bars
Line frequency
Slip frequency

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(SPF)
(RBPF)
(LF)
(SF)

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AC Motors
Frequency analysis of input current

current clamp

In order to find 2 X slip sidebands around FL, a analyzer


with high resolution, and preferably zoom around 50 Hz
is needed.
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D.C. Motor
Faults possible to detect with vibration analysis:
Broken field winding
Bad SCRs
Loose connections
Loose or blown fuses
Shorted control cards

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Identification
For 3 phase rectified D.C. motors
Broken field winding, Bad SCRs, Loose connections
Peaks at 6.LF
Loose or blown fuses, Shorted control cards
Peaks at 1.LF to 5.LF

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Synchronous time averaging


-suppresses vibrations not synchronous with the measured object.

Roll 2

Sampling always starts at


tacho signal from roll 1.

RPM
VIB

Roll 1
3

1X

2X

3X
1X

One measurement

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3X

Average of 10 measurements
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Enveloping
Detects low amplitude high frequency repetitive
bearing or gear mesh defects.
These defects emit repetitive low energy impact
signals that are highly pulse shaped and of very
short duration. They generate harmonics in the
very high frequency ranges.
These techniques filter out low frequency
vibration energies and therefore isolate &
emphasize specific high frequency signals.

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ISO 2372
Class

Class

Class

Class

Class

Class

Limits

1 Step

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Case - 1 Pump Impeller Wear


Summary
This case documents a 100 hp monitored over a period of 2
years (1500 rpm).
An increase of overall vibration levels and spectrum showed
high vane pass levels of 3 x RPM.

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The pump has 3 vanes on the impeller and an internal


inspection indicated impeller wears.
Impeller changed and both the overall levels of vibration and
the vane pass frequency returned to normal, acceptable levels.

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Analysis
Overall Vibration Levels:
Overall vibration levels were on the boarder line of being in an
alarm state for several months and remained stable, it was
decided to monitor closely. Then suddenly overall vibration
levels jumped to 0.95 inch/sec ie 390 % change.

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Vibration Spectrum :
The frequency spectrum collected from the pump inboard
bearing shows a predominant peak at a frequency of 3000
rpm. The spectral plot showing the historical growth in
amplitude of this predominant peak.
It is noted that the machine deterioration appears more severe
on the basis of overall readings than on the basis of the
frequency spectrums.

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One possible explanation for the observation is that there was


an increase in vibration amplitudes at frequencies beyond the
range.

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Theoretical Consideration:
Problems with blades and vanes are usually characterized by
high vibration or near the harmonic frequency
corresponding to the rotation speed X No. of blades.
Blade pass frequency usually exists in normal operating
machines, but harmonics usually indicates problem.

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Problem Diagnosis:
The data collected pointed towards the pump impeller as the
source of high vibrations because of dominant peaks at the
blade pass frequency as well as growing side band harmonics.

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Results
Corrective Action:
The pump impeller was removed and replaced.
Findings:
Overall vibration reading taken after repair amplitudes
significantly reduced.

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Conclusions
The objective of this case was to demonstrate the concept that
the blade pass frequency (No. of blades x shaft speed) and
surrounding harmonics gives an indication of impeller
condition. This case over all vibration increases trend
stopped the machine and changed impeller.

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Vibration signature of the pump took on a new shape without


high amplitudes at blade pass frequency and the overall
vibration levels returned to acceptable levels.

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