2 Vibn Analysis Basics
2 Vibn Analysis Basics
2 Vibn Analysis Basics
What Is Vibration?
It is the response of a system to an internal or external force which causes the system to oscillate.
Displacement
Upper Limit
Amplitude:
It is the magnitude of vibration signal. Units: Micron, MM/Sec, M/Sec2
Amplitude
- How much is it vibrating? Size (severity) of the problem. is it vibrating? Cause of the vibration.
Frequency Measurement
60 RPM
= 1 Rev / s
= 1 Hz
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
A
B C
a
t
+ a
v t
Acceleration :
DISPLACEMENT
10
1 VELOCITY
.1
.01
.001
ACCELERATION
60
600
6000
60000
Scales Of Amplitude
Peak
RMS
Peak to Peak
Av.
a 2a 0.707 a 0.637 a
Vibration Transducers
Produces electrical signal of vibratory motion
Proximity Probe
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
Velocity Probe
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
Accelerometer
Produces signal proportional to acceleration of seismic mass. Extremely linear amplitude sense. Large Frequency range Smaller in size
Phase
What Is Phase?
Phase is a measure of relative time difference between two sine waves.
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.
Step - 1
The tachometer senses the notch in the shaft and triggers data collection. At this point force equals zero.
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.
Step - 3
The high spot rotates 90 additional degrees, the force experience by the sensor is again zero.
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.
Step - 5
The high spot rotates 90 additional degrees to complete its 360 revolution, the force experienced by the sensor is again zero.
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
What Is FFT?
Known as Fast Fourier Transformation. Developed by J.B. Fourier in 1874.
FFT mathematically converts overall complex signal into individual amplitudes at component frequencies
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.
Pure sinus
CPM
2 sine waves
CPM
Pure sinus
1.41421
0.900984
x i
spec
-1.41421 0
100
1.06721e-008
0
trace 1
400
CPM
3 sine waves
1
x i
spec
1.17033e-008
0
400
CPM
Complex motion
14.1221
3.75895
x i
spec j
-14.7102 0
200
trace 1
0.00679134
0
400
CPM
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.
Conversion Of Spectrums
Displacement Displacement - Microns - Microns Speed - 2889 RPM
Velocity - mm/s
Acceleration - m/s2
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.
Unbalance
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
Types Of Unbalance
Static Unbalance Couple Unbalance Overhang Rotor Unbalance
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
Correction
Can be corrected by one balance weight in one plane of rotor center of gravity.
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.
Correction
Detection:
High horizontal & axial vibration Dominant frequency at 1x RPM Axial readings will be in phase but radial phase readings might be unsteady.
Correction
Overhung rotors might be having both static and couple unbalance and each of which requires correction.
Misalignment
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.
Types Of Misalignment
1. Off set
2. Angular
Diagnosis Of Misalignment
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.
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.
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.
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).
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.
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.
Mechanical Looseness
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.
Types
1. Structural frame/base looseness (1X) 2. Cracked structure/bearing pedestal (2X)
3. Rotating looseness - Loose bearing/improper fit
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.
Analysis1. 2X RPM amplitude is > 150% of 1X RPM amplitude in radial direction. 2. Amplitudes are somewhat erratic. 3. 2X RPM phase somewhat erratic.
3. Rotating looseness
Caused by1. Loose rotor. 2. Bearing loose in the housing. 3. Bearing loose in the shaft. 4. Excessive bearing internal clearance.
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.
Journal Bearing
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.
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
1X 2X
frequency
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.
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.
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.
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
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.
FTF
1.
2
d.
D
RPM = Shaft rotation . RPM d = Rolling element diameter D = Pitch diameter N = No. of rolling elements
BSF
D . 1 2. d N. FTF
BPFO
BPFI
N. ( RPM - FTF)
F = Contact angle
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
Gear Box
Gear box
Z1
RPM1
RPM2
Z2
Gear box
1/Rps Z.Rps velocity velocity Z.Rps-Rps Z.Rps-2 Rps Z.Rps+Rps
Z.Rps+2 Rps
frequency
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.
Normal Spectrum
Tooth Wear
GMF may not change High amplitudes of side bands Presence of natural frequency of gear (fn)
Excites GMF, fn & their side bands High amplitudes of side bands Sideband spacing reveals the defective gear or pinion.
Gear Misalignment
Excites harmonics of GMF with side bands Amplitudes 2GMF or 3GMF higher than 1GMF
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.
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.
Belt Drive
d D
Belt Drive
Eccentric sheaves
force
Eccentric sheaves will generate strong 1X radial components. A common condition. Looks like unbalance, but shows at both sheaves.
Belt Drive
Sheave misalignment
Off-set
Angular
Fans
Fan Blade Pass Frequency = RPM x no. of fan blades (FBPF)
Mainly radial vibrations FBPF with 1X RPM sidebands.
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.
Electrical Motors
AC Motors
Asyncronous AC motors Running speed:
RPM sync 120 f p
AC Motors
All electrical machines vibrates at 2 . line frequency.
The reasons are expanding and collapsing magnetic fields.
AC Motors
Coast Down Test
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
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.
D.C. Motor
Faults possible to detect with vibration analysis:
Broken field winding Bad SCRs Loose connections Loose or blown fuses Shorted control cards
Identification
For 3 phase rectified D.C. motors
Broken field winding, Bad SCRs, Loose connections Peaks at 6.LF
Roll 2
RPM VIB
Roll 1
3
1X
2X
3X
1X 2X 3X
One measurement
Average of 10 measurements
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.
ISO 2372
Class Limits Class Class Class Class Class
1 Step