Cat Ii
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Cat Ii
ACTIVITY BOOK
CATEGORY II
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Table of Contents
VIBRATION FUNDAMENTALS ........................................................................................... 4
WINDOWING .............................................................................................................. 17
AVERAGING ................................................................................................................ 18
DIAGNOSING MISALIGNMENT....................................................................................... 29
DIAGNOSING LOOSENESS............................................................................................ 30
BELTS ........................................................................................................................ 35
VIBRATION FUNDAMENTALS
[1] Circle the RMS level on this chart.
[2] True or False: The peak-peak level is always twice the peak level.
A. True
B. False
A. 10 Hz
B. 5 Hz
C. 0.2 Hz
D. 2 Hz
[3] The measurement that relates to the rate of change of the vertical movement of the shaft in the
bearing is...
A. Displacement
B. Velocity
C. Acceleration
[4] The measurement that is proportional to the stress of the shaft on the bearing is...
A. Displacement
B. Velocity
C. Acceleration
[5] The measurement that is proportional to the force of the shaft on the bearing is...
A. Displacement
B. Velocity
C. Acceleration
[6] Which two vibration measures are 180 degrees out of phase?
A. Displacement and Acceleration
B. Velocity and Acceleration
C. Displacement and Velocity
D. All of the above
[7] A spectrum has a peak at 100 Hz of 5 mm/sec rms. Calculate the corresponding vibration levels in
the units listed below:
in/sec pk_________________________________________________________________________
G’s rms__________________________________________________________________________
[8] It is understood that vibration severity is proportional to the velocity value. Which of the following
vibration levels is the most severe? (They were all recorded at the running-speed peak of a
1485 RPM motor.)
A. 10 mm/sec rms
B. 0.51 in/sec pk
C. 120 um pk-pk
D. 0.12 g’s rms
[2] What is the phase relationship between the following two signals?
A. In phase
B. 180 degrees out of phase
C. 90 degrees out of phase
A. Lead
B. Lag
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[2] Please name at least two ways to calculate the RMS Overall level
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________________________________________________________________________________________
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[2] If the 10X peak is at 2500 CPM, the running speed of the machine is _________________ CPM
A. 250 CPM
B. 2500 CPM
C. 4.2 CPM
[3] Sketch: Draw a 2 Hz sine wave with amplitude of 1 mm/sec. Draw the corresponding spectrum on
the chart below in mm/sec rms. Annotate the y-axis (show the min and max value on the graph
scale.)
[4] What is the amplitude of the peak in the spectrum you have sketched (state the units)?
________________________________________________________________________________________
_
[5] The following “order normalized” spectrum came from a motor driving a pump at 1485 RPM via a
flexible coupling. Calculate the frequency of the peak at 6X: ____________________ CPM
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Vibration Training Activity Booklet – CAT II Page 9 of 37
[1] If the following compressor ran at 1485 CPM, and there are 12 vanes on the impeller, calculate
the compressor vane-pass rate: _______________ CPM ______________ Hz ______________ X
[2] If the following fan had 10 blades, and the motor RPM was 1485, calculate the fan blade-pass
forcing frequency _______________ CPM ______________ Hz ______________ X
[3] If there were 10 vanes on the following compressor, and the compressor vane rate was 29,700 CPM,
calculate the RPM of the compressor ________________________ CPM
[4] If the pulley on this motor had a 100 mm diameter, and the pulley on the pump had a
350 mm diameter, and the motor speed was 2970 RPM, calculate the speed
of the pump: __________________________________ CPM
[5] If the motor speed was 1480 RPM, and the input gear of the gearbox had 39 teeth, and the pinion
had 15 teeth, and the compressor had 12 vanes, provide the following details:
[6] The two-stage gearbox below has the number of teeth on each gear and pinion as shown. From
this information, and the fact that the motor speed is 1450 RPM, calculate the following
information:
Stage one gearmesh frequency: ____________________ CPM
UNDERSTANDING SIGNALS
[1] Sketch: Imagine a machine that generates a 2 Hz signal of 2 mm/sec and a second 2 Hz signal of
1 mm/sec. There is 0 degrees phase angle between the two signals.
Draw the resultant time waveform and spectrum in mm/sec rms. Annotate the y-axis (show the
min and max value on the graph scale.)
[2] Question: What is the amplitude of the peak in the spectrum you have sketched (state the units)?
________________________________________________________________________________
[3] Sketch: Now imagine that the two signals were 180 degrees out of phase with each other. Draw
the resultant time waveform and spectrum in mm/sec rms. Annotate the y-axis (show the min and
max value on the graph scale.)
[4] Question: What is the amplitude of the peak in the spectrum you have sketched (state the units)?
________________________________________________________________________________
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Vibration Training Activity Booklet – CAT II Page 13 of 37
[8] If a signal of 200 Hz was varying in amplitude at a rate of 20 Hz, what pattern would you see in the
spectrum?
A. A peak at 200 Hz, 400 Hz, 600 Hz, etc.
B. A peak at 200 Hz and 20 Hz.
C. Peaks at 180 Hz, 200 Hz and 220 Hz.
[9] Two signals very close to each other in frequency will cause
A. Subtraction
B. Harmonics
C. Beating
D. Amplitude modulation
[10] Describe what you would hear if an electric motor generated signals at 99 Hz and 100 Hz
A. Your last sound
B. Nothing
C. A throbbing sound with a period of 1 second
D. Amplitude modulation
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SIGNAL PROCESSING
Useful information:
[1] If the first graph is the spectrum of the raw, unfiltered signal coming from the transducer, and
that signal was put through a filter such that the spectrum in the lower graph was the result, what
sort of filter must have been used?
A. High pass
B. Low pass
C. Band pass
D. Notch (band stop)
[2] If a cyclical signal, which reaches its peak every second, was sampled every second, what would the
waveform look like?
A. A straight/flat line
B. It would be a sine wave, with a frequency of 1 Hz
C. Triangular, as it went from the top of one cycle to the bottom of the next
[4] For the same Fmax, if you increase the number of lines of resolution...
A. The measurement will take longer to acquire
B. The test time will not change
C. The measurement will take less time to acquire
[5] Why shouldn't you always collect the highest resolution measurement possible?
A. The test takes longer
B. The data takes more room in the database
C. The data takes longer to unload from the data collector
D. All of the above
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[6] If a spectrum had 1600 lines of resolution, how many samples were in the time record?
A. 1024 samples
B. 2048 samples
C. 4096 samples
[7] If the record length is 10 seconds, and there were 1024 samples, what is the Fmax?
A. 40 Hz
B. 40 CPM
C. 400 Hz
D. 4000 Hz
[8] If the Fmax is 10,000 Hz and you have a 1600 line spectrum, how long does it take to sample the
vibration signal if you have one average only?
A. Not enough information
B. 6.25 seconds
C. 1.6 seconds
D. 0.16 seconds
[9] If the Fmax is 120 Hz and you have a 3200 line spectrum, how long does it take to sample the
vibration signal if you have 10 averages (no overlap)?
A. 267 seconds
B. 27 seconds
C. 12 seconds
D. 6 seconds
[10] What Fmax and Lines of resolution settings are required to separate vibration signals of 100 Hz and
100.50 Hz? (assume that a Hanning window will be used):
________________________________________________________________________________
[11] If a spectrum had a peak at 250 Hz, and the spectrum had 800 lines and Fmax = 800 Hz, and the
window was turned of, which of the following is true about the actual source of vibration?
A. 250 ±0.5 Hz
B. 250 ±1 Hz
C. 250 ±1.5 Hz
D. 250 ±2 Hz
WINDOWING
[1] We experience leakage because:
A. The signal does not begin and end at zero in the time record – it is “finite”.
B. There are errors in the FFT calculation.
C. Time waveforms can often have a lot of noise.
[2] The window most commonly used when route testing rotating equipment is:
A. Hanning
B. Flat top
C. Exponential
D. Uniform/Rectangular/No window
[3] The window most commonly used for bump tests is:
A. Hanning
B. Flat top
C. Exponential
D. Uniform/Rectangular/No window
[5] The primary reason for windowing the time waveform is:
A. To increase frequency accuracy.
B. To improve amplitude accuracy.
C. To correct the leakage phenomenon.
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AVERAGING
[1] How many averages should one normally use when using linear averaging with an Fmax
of 10,000 Hz?
A. 2 averages
B. 5-10 averages
C. 50 averages
[2] The most commonly used averaging method used for routine data collection is:
A. Time synchronous averaging
B. Linear averaging
C. Peak-hold averaging
[3] True or False: Linear averaging works by averaging the time waveform.
A. True
B. False
[4] True or False: Linear averaging removes noise from the spectrum
A. True
B. False
[5] When performing a bump test, which averaging method should be used?
A. Time synchronous averaging
B. Linear averaging
C. Peak-hold averaging
D. Free run averaging
[6] How many averages should normally be used when using time synchronous averaging?
A. 4-6 averages
B. 10 averages
C. 20 averages
D. 100 averages (or more)
[7] True or False: Time synchronous averaging removes noise from the waveform
A. True
B. False
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[2] True or False: I can use the same sensor for all of my vibration tests.
A. True
B. False
[5] When a signal is integrated (accel-vel) what happens to low frequency (<160 Hz) signals?
A. They are increased in amplitude
B. They are reduced in amplitude
C. The amplitude is not affected
[6] When integrating from acceleration to velocity, why is a high pass filter?
A. To filter out noise in the signal which is caused by machine 'rumble'
B. To filter out electrical noise
C. To filter out the low frequency signals that are amplified during the integration process
[7] What type of sensor measures the relative movement between the shaft and bearing?
A. Displacement non-contact eddy current probe
B. Velocity sensor
C. Accelerometer
[8] What is the difference between a charge-mode accelerometer and 'ICP' accelerometers?
A. Charge mode accelerometers require an external amplifier
B. The frequency response of an ICP accelerometer is far greater
C. ICP accelerometers are better suited to high-temperature applications
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[9] What is a piezovelocity sensor and why might someone choose to use one instead of an
accelerometer?
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________________________________________________________________________________
[10] Which transducer is best suited to a machine tool application with very low vibration?
A. 10 mV/g
B. 100 mV/g
C. 1000 mV/g
[11] What would happen if you used a 10 mV/g sensor on the quiet machine tool?
A. The machine tool would appear to vibrate much more than it actually did
B. The voltage output would be small, and the amplitude resolution of data would be
unacceptable
C. The sensor would 'saturate' and the vibration data would be poor
[12] What would happen if you used a 1000 mV/g accelerometer on a noisy rock crusher?
A. Sparks would fly from the transducer leads
B. The data collector would overload and may be damaged
C. The sensor would 'saturate' and the vibration data would be poor
[13] True or False: The frequency response is the same regardless of the sensitivity.
A. True
B. False
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[3] If you cannot access a suitable test location for the sensor you should...
A. find another machine to monitor - that one is too hard.
B. buy a longer 'stinger' so that you can reach in to the best location.
C. mount the sensor anywhere that it vibrates - it is better than nothing.
D. permanently mount a sensor, and connect it to a junction box.
[4] Circle the best transducer mounting point from the available options: A B C D
[6] Which is the best method of mounting a sensor (the best frequency response)?
A. Stinger, or probe tip
B. Flat magnetic mount
C. Two-pole magnetic mount
D. Stud mount
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[2] When considering the vibration sensor, what is the settling time?
A. A setting on my data collector I have never understood
B. The time it takes the sensor to convert the entire vibration pattern.
C. The time it takes for the transducer to generate a stable output.
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________________________________________________________________________________
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[5] What type of phase measurement is often more convenient when measuring phase to diagnose
typical machine faults?
A. Absolute phase
B. Relative phase
[6] True or False: A strobe should be used as a phase reference when balancing.
A. True
B. False
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[4] What is wrong with this machine? Please briefly explain why you have come to this conclusion.
________________________________________________________________________________
________________________________________________________________________________
[5] What is wrong with this machine? Please briefly explain why you have come to this conclusion.
________________________________________________________________________________
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DIAGNOSING IMBALANCE
[1] If a machine (not overhung) is out of balance, the spectrum will have...
A. peaks at 1X, 2X, and 3X.
B. a high peak at 1X in the axial direction.
C. a high peak at 1X in the vertical and horizontal direction.
D. a high peak at 2X.
[9] If I have a large 24 Hz (1440 RPM) motor-pump with a peak at running speed of
3.0 mm/sec rms (and the fault was suspected to be imbalance), according to the chart below, what
is the severity of this condition?
DIAGNOSING ECCENTRICITY
[1] If a sheave/pulley or rotor is eccentric, the spectrum will have...
A. peaks at 1X, 2X, and 3X.
B. a high peak at 1X in the axial direction.
C. a high peak at 1X in the radial directions.
D. a high peak at 2X.
DIAGNOSING MISALIGNMENT
[1] If a machine has angular misalignment, in the axial direction the spectrum will have...
A. peaks at 1X, 2X, 3X, 4X, etc.
B. a high amplitude peak at 1X.
C. high amplitude peaks at 1X and 2X.
D. a high peak at 2X only.
[2] Describe the phase relationship across the coupling when angular misalignment exists.
A. In-phase in the radial direction, and out-of-phase in the axial direction.
B. Out-of-phase in the radial and axial directions.
C. In-phase in the axial direction and out-of-phase in the radial directions.
D. In-phase in the radial and axial directions.
[3] If a machine has parallel misalignment, in the radial directions the spectrum will have...
A. peaks at 1X, 2X, 3X, 4X, etc.
B. a moderate-high amplitude peak at 1X and a high 2X peak.
C. moderate amplitude peaks at 1X and 2X.
D. a high peak at 2X only.
[4] Describe the phase relationship across the coupling when parallel misalignment exists.
A. In-phase in the radial direction, and out-of-phase in the axial direction.
B. Out-of-phase in the radial and axial directions.
C. In-phase in the axial direction and out-of-phase in the radial directions.
D. In-phase in the radial and axial directions.
[7] Why are imbalance faults on overhung machines sometime misdiagnosed as misalignment faults?
A. Because it is hard to correctly align overhung machines.
B. Because both conditions result in 1X vibration in the axial direction.
C. Because both conditions result in 2X vibration in the axial direction.
D. Gee, I don't know!
[2] If a shaft is bent, what will be the phase relationship when measured at either end of the machine?
A. In-phase in the vertical direction, but out-of-phase in the horizontal direction.
B. In-phase when measured axially.
C. Out-of-phase when measured axially.
D. Phase is not a useful tool for diagnosing a bent shaft.
DIAGNOSING LOOSENESS
[1] Name one of the causes of rotating looseness.
A. Motor not bolted down securely.
B. Loose cowling or other metallic structure.
C. Wear within a rolling element bearing.
D. Pedestal bearing not bolted down sufciently.
[3] If you witnessed a 1X peak in the vertical direction, and a much stronger 1X peak in the horizontal
direction, which would you suspect?
A. Rotating looseness.
B. Non-rotating looseness.
C. Structural looseness (foundation flexibility).
D. Pedestal bearing looseness.
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[4] If you witnessed a 1X, 2X, and 3X peak, which would you suspect?
A. Rotating looseness.
B. Non-rotating looseness.
C. Structural looseness (foundation flexibility).
D. Pedestal bearing looseness.
DIAGNOSING RESONANCE
[1] What is the diference between a natural frequency and resonance?
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[2] If the running speed of the machine was changed so that it now coincided with a natural frequency,
how would the vibration amplitude change?
A. It will remain unchanged
B. It will increase if the machine was out-of-balance and the machine speed was decreased.
C. It will decrease in amplitude due to resonance
D. It will increase in amplitude due to resonance
[3] True or false: Bearing forcing frequency calculations are 100% accurate.
A. True
B. False
[4] A defect on a ball or roller will often cause which pattern in a spectrum?
A. High 1x
B. Cage rate vibration
C. Non synchronous peak with cage rate sidebands
D. Non synchronous peak with 1x sidebands
[5] If we knew that BPO was 3.2X and BPI was 4.8X, how many balls are there?
A. There must be 8 balls (3.2 + 4.8 = 8)
B. There must be 10 balls (2 + 8 = 10)
C. There must be 7 balls (3 + 4 = 7)
[6] If you detected changes in vibration from a bearing at ultrasonic frequencies (and you don’t see
anything in other parts of the spectrum)...
A. you should change the bearings at your next opportunity
B. you should keep dogs away from the machine - it may hurt their ears
C. you should continue monitoring for additional signs of wear
[7] If the inner race is spinning, which fault is described by these peaks in a spectrum: 3.2x, 4.2x, 5.2x,
8.4x, 12.6x
A. Outer race
B. Ball fault
C. Inner race
D. Cage fault
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[2] An eccentric rotor (with a rotating differential air gap) will produce...
A. a high 1X peak at the motor running speed
B. a peak at the rotor bar frequency with twice line-frequency sidebands
C. increased amplitude at 1X vibration and twice line frequency, with pole-pass sidebands
D. harmonics of 1X with pole-pass sidebands
[3] A motor (not on a VFD) turns at 1740 RPM. The pole-pass frequency is…
A. 60 RPM
B. 24 Hz
C. 29 Hz
D. 240 RPM
GEARBOX ANALYSIS
[1] The input gear of a single reduction gearbox has 32 teeth. Which of these patterns would
you expect to see in the spectrum?
A. A peak at 32x only
B. Peaks at 8x, 16x, 24x and 32x
C. Peaks at 31x, 32x, 33x
D. None of the above
[2] Why is time waveform analysis useful in analyzing vibration from gearboxes?
A. You can easily identify the shaft speed from the time waveform
B. You can see the pattern of wear on the teeth
C. You can detect damage to individual teeth
D. Time waveform analysis is good for all rotating components so it must be good for
gearboxes
[3] What efect is present in the time waveform from this gearbox?
A. Looseness
B. Beating
C. Random vibration
D. Amplitude modulation
[4] What is the best tool for detecting cracked or broken gear teeth?
A. Motor current analysis
B. Perform thermographic analysis on the lubricant
C. A wrench and a large hammer
D. Time waveform analysis
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BELTS
[1] The 'belt rate' forcing frequency is...
A. lower than the machine RPM
B. higher than the machine RPM
C. the same as the output RPM
[4] If two sheaves/pulleys are not aligned correctly, the vibration pattern will produce...
A. a strong 1X component in the radial directions
B. a series of harmonics of the belt rate
C. a strong 1X component in the axial direction
D. strong 1X, 2X, and 3X peaks
[5] If a belt resonance coincides with the sheave/pulley RPM, the vibration pattern will produce...
A. a strong 1X component in the radial directions
B. a series of harmonics of the belt rate
C. a strong 1X component in the axial direction
D. strong 1X, 2X, and 3X peaks
MAINTENANCE PRACTICES
[1] In a general sense, a plant that wishes to remain competitive will try to move from a
________ mode to a ________ mode of operation.
A. predictive / preventive
B. reactive / proactive
C. run to failure / preventive
D. proactive / predictive
[7] Which maintenance philosophy can actually reduce plant reliability compared with doing nothing?
A. Root cause failure analysis
B. Predictive maintenance
C. Preventive maintenance
D. Proactive maintenance
[9] Which maintenance philosophy would result in lower spare parts cost?
A. Breakdown maintenance
B. Predictive maintenance
C. Preventive maintenance