Vibration Monitoring Analysis
Vibration Monitoring Analysis
Vibration Monitoring Analysis
Vibration Monitoring
What is Vibration ?
It is motion of mechanical parts back and
forth from its position of rest /neutral
position.
Vibration Monitoring
What causes Vibration ?
Induced Force
&
Freedom for Movement
Vibration Monitoring
Harmful Effects of Excess vibration
• Increased load on BRGs: Reduced BRG Life
• Higher Forces on Mountings:
Foundation Loosening and Damage of
Support Structure
• Increased Stresses of M/c : Risk of fatigue
components
Vibration Monitoring
Harmful Effects of Excess vibration
• Decreased Equipment efficiency.
• Reduced Output Quality.
• Increased Maintenance Cost due to
more Component Failures and
Unplanned Operations
• Unsafe Operating Environment
Vibration Monitoring
Problem Identifications
• Unbalance
• Misalignment
• Mechanical Looseness
• Antifriction / Sleeve Bearing Defects
• Gear Defects
Vibration Monitoring
Problem Identifications
• Belt Defects
• Impeller / Blade Defects
• Bent Shaft
• Electrical Problems
• Resonance
Vibration Monitoring
Fundamental Realities
• All Machines vibrate.
• An increase in vibration level is a sign of
trouble & amplitude of Vibration depends on
the extent of defect in the machinery
components
• Each trouble will create vibration with different
characteristics
VIBRATION FUNDAMENTALS
90
Upper Limit
Lower Limit
Period(T) 270
(1 complete cycle)
Characteristics of Vibration
• Vibration characteristics are
Displacement
Amplitude
Velocity
Acceleration
Frequency Hz or CPM
Displacement
Velocity
Acceleration
FFT
FAST FOURIER TRANSFORM.
Rolling
Imbalance Element
Bearing
Gearmesh
Coupling
chatter
Resultant Complex
Waveform
Time
Spectrum Analysis
of resolution
e
Frequency Fmax
Spectrum Data Collection Time
• FFT Calculation Time = Time to calculate
FFT from Time Waveform [assuming no
overlap processing]
OA = A1 2 + A2 2 + ………………………+An 2
NBF
OA=Overall level of Vibration Spectrum , Ai = Amplitude of each FFT line
n = No. of FFT Lines of resolution , NBF= Noise Bandwidth for Window chosen
NOTE: Don’t be concerned about the math,
the condition monitoring instrument
calculates the value. What’s important to
remember is when comparing overall
vibration signals, it is imperative that both
signals be measured on the same frequency
range and with the same scale factors.
What is Phase?
• The position of a vibrating part at a given
instant with reference to a fixed point or
another vibrating part.
• The part of a vibration cycle through which
one part or object has moved relative to
another part.
C
A B
A 5 Microns, 10 degrees
B 7 Microns, 12 degrees
C 25 Microns, 175 degrees
Bolt at C is loose
Vibration Analysis of
Common Problems
Vibration Analysis
Unbalance
• Amplitude proportional to the amount of
unbalance
• Vibration high normally in radial direction
(may be also in axial direction incase of
overhung and flexible rotors ).
• 1* RPM vibration is greater than 80%
(normally) of the overall reading.
Vibration Analysis
Unbalance
• Horizontal and vertical 1* RPM amplitude
should be nearly same, although it also
depends on system rigidity on the
particular direction.
• Other frequency peaks may be less than
5% of the 1*RPM amplitude
• Phase shift of 90 deg. When sensor
moves from horizontal to vertical.
UNBALANCE
• Operating conditions such as load, flow
condition and temperature effect
unbalance
– Balance under normal operating conditions
• Changes in track and pitch angle of fan
blades can result in “Aerodynamic
Unbalance”
Typical Spectrum For
Unbalance
MISALIGNMENT
• Looseness produces
2X RPM Freq.
Vibration Analysis
Mechanical Looseness
Caused by looseness in bearing housing bolts and
cracks in the frame structure.
PROTECTION
PERIODIC CONTINUOUS
NETWORK DCS
SOFTWARE
PdM TECHNOLOGIES CMMS
Overall Data Acquistion
4-20mA
MONITOR
THE DCS
DCS OUTPUT
time waveform
Overall Data Trends-
this is what the DCS records
hi alarm
lo alarm
Data Collector
Vibration Spectrum
transducer
time waveform
Band Alarms, associate with each rotating element
hi alarm
lo alarm
frequency bands
Band Trending, the new way forward
hi alarm
lo alarm
CH. 1 CH. 2 CH. 1 CH.2 CH. 1 CH. 2 CH. 1 CH. 2 CH. 1 CH. 2 CH. 1 CH. 2 CH. 1 CH. 2
CH. 1 CH. 2 CH. 1 CH.2 CH. 1 CH. 2 CH. 1 CH. 2 CH. 1 CH. 2 CH. 1 CH. 2 CH. 1 CH. 2
DATA VIBRATION
LOGGER ANALYSER
BFP ID
FS HP LP GEN EX
BFP FD
CWP PA
TURBINE STATOR END GATEWAY
SUPERVISORY WINDING AUXILIARIES
TO CMMS
Plant Integration with LAN or WAN
DCS ENGINEERING ODYSSEY
CLIENT SERVER
VIBRATION
ETHERNET ANALYSER
GATEWAY
TG 1 TG 2 TG 3 TO CMMS
ANURAKSHAN
NETWORKING THE INFORATION - LAN
/ WAN e.g.
RIHAND
TALCHER
PLANT
OPERATIO
NS
VINDHYACHAL
NOIDA HQ
GATEWAY CM CELL
TO CMMS
ANURAKSHAN
KAYAMKULAM
UNCHAHAR
Using PlantLink
Digital Picture of Plant
Hyperlink to
equipment
Hierarchy
Click on Measurement
Label to link to plots or
other views.
Information however you want it !
X-Window Screen Captures
Scenario of Instruments &Sensors & Probes
• Velocity sensors are made in India
• Accelerometers range over 150 types
– standard
– Low frequency
– High temperature (Gas Turbines)
– Special application
• Eddy current probes - comprehensive range
• Others available for process measurement
Vibration Datacollectors
Many vendors
Select on ‘Fitness
for Purpose’
Intrinsic Safety
Dust & Moisture proof
Diagnostic Capability