VIBRATION ANALYSIS
BASICS
Presented by : H.S.A
Topics:
Introduction to Vibration Theory
Topics:
Introduction to Vibration Theory
Basic Terminology & Practices
Topics:
Introduction to Vibration Theory
Basic Terminology & Practices
Basic Fault Identification
Topics:
Introduction to Vibration Theory
Basic Terminology & Practices
Basic Fault Identification
Case History Examples (show from MT)
Topics:
Introduction to Vibration Theory
Basic Terminology & Practices
Basic Fault Identification
Case History Examples (Show from MT)
Advanced Topics
Topics:
Introduction to Vibration Theory
Basic Terminology & Practices
Basic Fault Identification
Case History Examples
Advanced Topics
Requested Topics ???
WHAT IS VIBRATION?
MOTION OF A BODY ABOUT A
REFERENCE POINT
For example,
SHAFT VIBRATION
CAUSED BY AN UNDESIRABLE
MECHANICAL FORCE
It's helpful to understand a little
about the signal processing
step in order to get the most
benefit from the Analyzer
VIBRATION
SOURCE
TRANSDUCER
ELECTRICAL
SIGNAL
TIME
WAVEFORM
INFORMATION
NEEDED FOR
ANALYSIS
SIGNAL
PROCESSING
SPECTRUM
PROBLEM
DETECTION
AUTOMATED
DIAGNOSTICS
MANUAL
DIAGNOSTICS
COLLECTION OF VIBRATION
MEASUREMENTS
Compare Across Points
5.3 mils
1.2 mils
2.3 mils
3.1 mils
Directional vibration on outboard bearing
Signal Processing Flow
Transducer
Amplitude
Waveform
Time
FFT
Amplitude
Spectrum
Data Collector/Analyzer
Frequency
Heavy Spot
Rotation
Time Waveform
Heavy Spot
Amplitude
+
Rotation
Time
1 revolution
Time Waveform
Amplitude
+
Heavy Spot
Time
360 degrees
Rotation
1 revolution
3600 rpm
3600 cycles per minute
60 Hz
60 cycles per second
1 order
one times turning speed
Time Waveform
Amplitude
+
Time
1000 rpm
1 revolution
Time Waveform
Amplitude
+
Time
1000 rpm
1 revolution
4 blades
vibration occurs 4 times per revolution
4 x 1000 rpm
vibration occurs at 4000 cycles per minute
=
4000 cpm
Time Waveform
Amplitude
+
12 tooth
gear
Time
1000 rpm
1 revolution
Time Waveform
Amplitude
+
12 tooth
gear
Time
1000 rpm
1 revolution
12 teeth are meshing every revolution of the gear
12 x 1000 rpm
=
=
vibration occurs at 12,000 cycles per minute
12,000 cpm = 200 Hz
+
0
Time
+
0
Time
+
0
Time
Time Waveform contains all the different
frequencies mixed together
+
Time
TIME WAVEFORM
AMPLITUDE VS TIME
We are now entering the
Frequency Domain
FFT - Fast Fourier Transform
We are now entering the
Frequency Domain
FFT - Fast Fourier Transform
Separates individual frequencies
We are now entering the
Frequency Domain
FFT - Fast Fourier Transform
Separates individual frequencies
Detects how much vibration at each
frequency
Amplitude
Frequency
Amplitude
Amplitude
Time
Amplitude
Time
Time
y
en c
u
q
Fre
Time
1x
Frequency
+
0
Time
+
0
4x
Frequency
Time
12x
Frequency
FREQUENCY SPECTRUM (or
FFT)
AMPLITUDE VS FREQUENCY
Amplitude
1.8
1.5
1.2
0.9
0.6
0.3
1000
2000
Frequency
3000
4000
VIBRATION TERMINOLOGY
AMPLITUDE
DISPLACEMENT
VELOCITY
ACCELERATION
FREQUENCY
HERTZ
CPM
ORDERS
PHASE (LAG)
DEGREES
HOW BAD IS IT?
(MOVEMENT)
(SPEED)
(FORCE)
Spectrum
Amplitude
WHERE IS IT
Frequency
(CYCLES / SECOND)
(CYCLES / MINUTE)
(MULTIPLES OF RUN SPEED)
TIME BETWEEN EVENTS
(ROTATIONAL MEASUREMENT)
What's an Fmax,
and why does it matter?
What's an Fmax,
and why does it matter?
Maximum Frequency of the Spectrum
What's an Fmax,
and why does it matter?
Maximum Frequency of the Spectrum
If you don't collect it, you can't analyze it
Fmax = low frequency
Fmax = high frequency
What's an Fmax,
and why does it matter?
Maximum Frequency of the Spectrum
If you don't collect it, you can't analyze it
Why not always collect the highest Fmax
possible?
Limitations of the analyzer
Takes extra data storage space
Reduces the Resolution of the Spectrum
What's the difference between
Acceleration, Velocity, & Displacemen
?
What's the difference between
Acceleration, Velocity, & Displacemen
?
The frequency range of interest
Acceleration
(high freq.)
Velocity
(general purpose)
Displacement
(low freq)
And let's not forget
Phase Analysis
Phase Comparison
In Phase:
180 Out of Phase:
o
Phase Comparison
In Phase:
180 Out of Phase:
o
Amplitude - A
+
0
Amplitude - A
+
Time
Amplitude - B
+
Amplitude - B
+
Time
Time
Time
180 Out of Phase:
In Phase:
A
A
B
Tach Pulse
Phase Measured
between the two
Time
360 degrees
Vibration Signal
Time for a demonstration:
Rotor kit / Strobe
data collection tips
Spectrum Analysis
1.8
1.5
1.2
0.9
0.6
0.3
1xRPM - BALANCE
2xRPM - ALIGNMENT
3-6xRPM - LOOSENESS
GEARS & ANTI FRICTION BEARINGS
6-30xRPM
30-50xRPM
1000
2000
Frequency
3000
4000
Vibration Spectrum and
Parameter Bands
2X
Bearing Bearing
Gears
Bearing
Amplitude
SubHarmonic 1X
1x
50x
Trend of
Bearings
2x
Trend of
Balance
5
mm/sec
Time
(Days)
1
mm/sec
Alarm
Time
(Days)
SELECTED FREQUENCY
BAND ALARMING
2X
Bearing Bearing
Gears
Bearing
Amplitude
SubHarmonic 1X
1x
50x
Trend of
Bearings
2x
Trend of
Balance
5
mm/sec
Time
(Days)
1
mm/sec
Alarm
Time
(Days)
OVERALL ALARM
AREA (ENERGY) UNDER THE SPECTRUM
'SHOTGUN'
METHOD, NO DIAGNOSTIC INFORMATION
ALARM LEVEL = 0.1 IN/SEC
PEAK - RMS
OVERALL VALUE
BEARING AND GEAR PROBLEMS WILL NOT GIVE EARLY
WARNING WITH OVERALL ALARMS
ENVELOPE ALARMING
CONSTRUCTED FROM BASELINE SPECTRA
"VARIABLE SHAPE ENVELOPING"
EFFECTIVE IN FINDING SMALL CHANGES
0.1 in/sec
Increase
200 % rise
over Reference
0.3 in/sec
Absolute
Value
.02 in/sec
Minimum
Value
Diagnosing Machine Faults
Imbalance
Diagnosing Machine Faults
Imbalance
Misalignment
Diagnosing Machine Faults
Imbalance
Misalignment
General Looseness or Wear
Diagnosing Machine Faults
Imbalance
Misalignment
General Looseness or Wear
Bearing Defects
Diagnosing Machine Faults
Imbalance
Misalignment
General Looseness or Wear
Bearing Defects
Gear Defects
Diagnosing Machine Faults
Imbalance
Misalignment
General Looseness or Wear
Bearing Defects
Gear Defects
and many more...
What is Imbalance?
Center of Shaft = Center of Mass
Heavy Spot
Center of Mass
Center of Shaft
Rotation
Types of Imbalance
Imbalance can be separated into two
components:
Static Imbalance:
(constant across rotor)
Couple Imbalance:
o
(opposite across rotor)
IMBALANCE
CHARACTERISTICS
IMBALANCE
CHARACTERISTICS
HIGH RADIAL PEAKS AT 1 X SHAFT RPM
IMBALANCE
CHARACTERISTICS
HIGH RADIAL PEAKS AT 1 X SHAFT RPM
LOW AXIAL VIBRATION AT 1 X SHAFT RPM
IMBALANCE
CHARACTERISTICS
HIGH RADIAL PEAKS AT 1 X SHAFT RPM
LOW AXIAL VIBRATION AT 1 X SHAFT RPM
LOW HARMONICS OF SHAFT RPM
IMBALANCE
CHARACTERISTICS
HIGH RADIAL PEAKS AT 1 X SHAFT RPM
LOW AXIAL VIBRATION AT 1 X SHAFT RPM
LOW HARMONICS OF SHAFT RPM
1 X RPM SINUSOIDAL PATTERN IN THE TIME WAVEFORM
IMBALANCE
CHARACTERISTICS
HIGH RADIAL PEAKS AT 1 X SHAFT RPM
LOW AXIAL VIBRATION AT 1 X SHAFT RPM
LOW HARMONICS OF SHAFT RPM
1 X RPM SINUSOIDAL PATTERN IN THE TIME WAVEFORM
CAN CAUSE OTHER FAULTS TO SHOW UP, ESPECIALLY
LOOSENESS
IMBALANCE
RADIAL VIBRATION
AT 1 X TURNING
SPEED IS MUCH
MORE SIGNIFICANT
THAN IN THE AXIAL
DIRECTION
Freq: 60.04
Order: 1.010
Spec: .390
What is misalignment?
Deviation from a common centerline during operation.
GRRR!
BEFORE
hmmm
!
AFTER
Types of Misalignment
Offset
Angular
Both
MISALIGNMENT
CHARACTERISTICS
MISALIGNMENT
CHARACTERISTICS
2 X SHAFT RPM MAY DOMINATE
MISALIGNMENT
CHARACTERISTICS
2 X SHAFT RPM AXIAL DOMINATES
HIGH AXIAL AT 1, 2 AND 3 X SHAFT RPM
MISALIGNMENT
CHARACTERISTICS
2 X SHAFT RPM AXIAL DOMINATES
HIGH AXIAL AT 1, 2 AND 3 X SHAFT RPM
HIGH RADIAL AT 1, 2 AND 3 X SHAFT RPM
MISALIGNMENT
CHARACTERISTICS
2 X SHAFT RPM AXIAL DOMINATES
HIGH AXIAL AT 1, 2 AND 3 X SHAFT RPM
HIGH RADIAL AT 1, 2 AND 3 X SHAFT RPM
HARMONICS OF SHAFT RPM ABOVE 4 X ARE
USUALLY LOW
MISALIGNMENT
CHARACTERISTICS
2 X SHAFT RPM AXIAL DOMINATES
HIGH AXIAL AT 1, 2 AND 3 X SHAFT RPM
HIGH RADIAL AT 1, 2 AND 3 X SHAFT RPM
HARMONICS OF SHAFT RPM ABOVE 4 X ARE
USUALLY LOW
PHASE READINGS SHOW A 180 DEGREE SHIFT
ACROSS THE COUPLING
MISALIGNMENT
2X IS DOMINANT
LOCATION OF
VIBRATIONS
VANE PASS IS DUE TO 11
BLADE PUMP IMPELLER
VANE PASS
Freq: 59.50
Order: 2.010
Spec: .640
Using Phase to distinguish Imbalance
from Misalignment
Cross Coupling Phase
180 deg out
GRRR
!
In Phase
MECHANICAL LOOSENESS
MULTIPLE HARMONICS OF RUN SPEED
RUN SPEED HARMONICS
1X, 2X, 3X, 4X, 5X, 6X, 7X, 8X
2X
3X
1X
5X
4X
6X
8X
7X
Discuss "Harmonics"
Bearing Fault Frequencies
Function of the Geometry of the Bearing
Outer Race
(BPFO)
Inner Race
(BPFI)
Ball Spin
(BSF)
Cage
(FTF)
ROLLER BEARING EXAMPLE
Freq: 441.03
Order: 7.390
Spec: .180
Discussion Topics:
Fault frequencies
Inner -vs- Outer race defects
"Side-band" analysis
Severity stages
GEARMESH FAULT
Freq: 106.89
Order: 21.00
Spec: .062
RESONANCE
So much to say and so little time
(lead in to advanced topics)
Typical Periodic Vibration Survey Flow
Database
Exception
Report
Data
Analysis
Route
Data
Collector
Automated
Diagnosis
Report
Generation
& Machine
History
Maintenance
Action
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