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Ludeca Machinery Fault Diagnosis Guide
Ludeca Machinery Fault Diagnosis Guide
Ludeca Machinery Fault Diagnosis Guide
©2011 PRÜFTECHNIK Condition Monitoring – Machinery Fault Diagnosis. Distributed in the US by LUDECA, Inc. • www.ludeca.com 1
Preface
© Copyright 2011 by PRÜFTECHNIK AG. ISO 9001:2008 certified. No copying or reproduction of this information, in any form whatsoever,
may be undertaken without express written permission of PRÜFTECHNIK AG or LUDECA Inc.
©2011 PRÜFTECHNIK Condition Monitoring – Machinery Fault Diagnosis. Distributed in the US by LUDECA, Inc. • www.ludeca.com 2
Unbalance
m Unbalance is the condition when the geometric centerline of a rotation axis doesn’t
coincide with the mass centerline.
Funbalance = m d ω2
1X
Radial
MP MP
A pure unbalance will generate a signal at the rotation speed and predominantly in
the radial direction.
©2011 PRÜFTECHNIK Condition Monitoring – Machinery Fault Diagnosis. Distributed in the US by LUDECA, Inc. • www.ludeca.com 3
Static Unbalance
→
U
The static unbalance is seen when the machine is not in
operation, the rotor will turn so the unbalance mass is
at the lowest position.
©2011 PRÜFTECHNIK Condition Monitoring – Machinery Fault Diagnosis. Distributed in the US by LUDECA, Inc. • www.ludeca.com 4
Pure Couple Unbalance
→ →
UΙΙ = -UΙ
-m
Pure couple unbalance is caused by two identical
S unbalance masses located at 180° in the transverse area of
the shaft.
→
UΙ b
Pure couple unbalance may be statically balanced.
©2011 PRÜFTECHNIK Condition Monitoring – Machinery Fault Diagnosis. Distributed in the US by LUDECA, Inc. • www.ludeca.com 5
Dynamic Unbalance
→
UΙΙ
m
→
UΙ
In practice, dynamic unbalance is the most common
form of unbalance found.
©2011 PRÜFTECHNIK Condition Monitoring – Machinery Fault Diagnosis. Distributed in the US by LUDECA, Inc. • www.ludeca.com 6
Documentation of balancing
.. after balancing
before ..
©2011 PRÜFTECHNIK Condition Monitoring – Machinery Fault Diagnosis. Distributed in the US by LUDECA, Inc. • www.ludeca.com 7
Overhung Rotors
1X
Radial
Dynamic unbalance in overhung rotors causes high 1X
Axial levels in radial and axial direction due to bending of the
shaft. The axial bearing signals in phase may confirm
this unbalance.
©2011 PRÜFTECHNIK Condition Monitoring – Machinery Fault Diagnosis. Distributed in the US by LUDECA, Inc. • www.ludeca.com 8
Unbalance location
©2011 PRÜFTECHNIK Condition Monitoring – Machinery Fault Diagnosis. Distributed in the US by LUDECA, Inc. • www.ludeca.com 9
Misalignment
1X 2X
MP MP
Axial
©2011 PRÜFTECHNIK Condition Monitoring – Machinery Fault Diagnosis. Distributed in the US by LUDECA, Inc. • www.ludeca.com 10
Angular Misalignment
1X 2X 3X
Axial
©2011 PRÜFTECHNIK Condition Monitoring – Machinery Fault Diagnosis. Distributed in the US by LUDECA, Inc. • www.ludeca.com 11
Parallel Misalignment
1X 2X 3X
Radial
©2011 PRÜFTECHNIK Condition Monitoring – Machinery Fault Diagnosis. Distributed in the US by LUDECA, Inc. • www.ludeca.com 12
Misalignment Diagnosis Tips
©2011 PRÜFTECHNIK Condition Monitoring – Machinery Fault Diagnosis. Distributed in the US by LUDECA, Inc. • www.ludeca.com 13
Alignment Tolerance Table
The suggested alignment tolerances shown above are general values based upon experience and should not be exceeded.
They are to be used only if existing in-house standards or the manufacturer of the machine or coupling prescribe no other values.
©2011 PRÜFTECHNIK Condition Monitoring – Machinery Fault Diagnosis. Distributed in the US by LUDECA, Inc. • www.ludeca.com 14
Shaft Bending
1X 2X
Axial
©2011 PRÜFTECHNIK Condition Monitoring – Machinery Fault Diagnosis. Distributed in the US by LUDECA, Inc. • www.ludeca.com 15
Rotating Looseness
Rotating looseness is caused by an excessive clearance between the rotor and the bearing
Radial
Journal bearing:
Rotation frequency
1X Harmonics and
sub Harmonics.
Radial
©2011 PRÜFTECHNIK Condition Monitoring – Machinery Fault Diagnosis. Distributed in the US by LUDECA, Inc. • www.ludeca.com 16
Structural Looseness
Structural looseness occurs when the machine is not correctly supported by, or well
fastened to its base.
MP
• Poor mounting
• Poor or cracked base
MP
MP MP • Poor base support
• Warped base
©2011 PRÜFTECHNIK Condition Monitoring – Machinery Fault Diagnosis. Distributed in the US by LUDECA, Inc. • www.ludeca.com 17
Resonance
Resonance is a condition caused when a forcing frequency coincides (or is close) to the
natural frequency of the machine’s structure. The result will be a high vibration.
1st form of natural 2nd form of natural flexure 3rd form of natural flexure
flexure
v v v
tx tx
t tx t t
©2011 PRÜFTECHNIK Condition Monitoring – Machinery Fault Diagnosis. Distributed in the US by LUDECA, Inc. • www.ludeca.com 18
Resonance
1 2
Resonance
Step-up
rev/min
Grad
Phase jump
MP MP
by 180°
rev/min
ϕ1 = 240° 2 ϕ2 = 60...80°
1. 1.
O. O.
©2011 PRÜFTECHNIK Condition Monitoring – Machinery Fault Diagnosis. Distributed in the US by LUDECA, Inc. • www.ludeca.com 19
Resonance Diagnosing Tests
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Resonance Diagnosing Tests
Bump Test:
s 1 2
Excitation – force pulse Response – component vibration
F/a 3
Double beat t t
5 ms 1
2 Decaying function
Shock component, natural vibration, vertical Frequency response, vertical Frequency response, horizontal
2nd mod.
Natural frequency, 1st mod.
vertical
Natural frequency,
horizontal
t
©2011 PRÜFTECHNIK Condition Monitoring – Machinery Fault Diagnosis. Distributed in the US by LUDECA, Inc. • www.ludeca.com 21
Journal Bearings
Journal bearings provides a very low friction surface to support and guide a rotor through a cylinder
that surrounds the shaft and is filled with a lubricant preventing metal to metal contact.
0,3-0,5X 1X
©2011 PRÜFTECHNIK Condition Monitoring – Machinery Fault Diagnosis. Distributed in the US by LUDECA, Inc. • www.ludeca.com 22
Rolling Element Bearings
1. Wear:
Wear
• Lifetime exceeded
• Bearing overload
• Incorrect assembly
• Manufacturing error
• Insufficient lubrication
Wear
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Rolling Element Bearings
2. Race Damage:
4
3
Roller bearing geometry and damage frequencies: 1 - Outer race damage
2
2 - Inner race damage
3 - Rolling element damage
©2011 PRÜFTECHNIK Condition Monitoring – Machinery Fault Diagnosis. Distributed in the US by LUDECA, Inc. • www.ludeca.com 24
Rolling Element Bearings
fn
BPFO 2⋅ BPFO 3⋅ BPFO 4⋅ BPFO
Sidebands at intervals of 1X
Outer race damage frequency BPFO as well as Inner race damage frequency BPFI as well as
harmonics clearly visible numerous sidebands at intervals of 1X.
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Rolling Element Bearings
Rolling elements rollover frequency BSF with Cage rotation frequency FTF and harmonics
harmonics as well as sidebands in intervals of FTF visible
©2011 PRÜFTECHNIK Condition Monitoring – Machinery Fault Diagnosis. Distributed in the US by LUDECA, Inc. • www.ludeca.com 26
Rolling Element Bearings
Lubrication Problems:
Major fluctuation in
• Race damage level of shock pulses
Lubricant contamination and damage
• Defective sealing frequencies
• Insufficient lubricant
Insufficient lubrication
• Underrating
→ Subsequent
small temperature
increase
©2011 PRÜFTECHNIK Condition Monitoring – Machinery Fault Diagnosis. Distributed in the US by LUDECA, Inc. • www.ludeca.com 27
Rolling Element Bearings
Incorrect mounting.
Shock pulse ↑
Bearing rings out of round, deformed. Air gap
Dirt
• Incorrect installation
• Wrong housing calculation
• Manufacturing error in bearing Fixed Floating
housing bearing bearing
Severe vibration
Bearing temperature
increases
Cocked bearing.
Axial 1X, 2X
and 3X.
• Incorrect installation
©2011 PRÜFTECHNIK Condition Monitoring – Machinery Fault Diagnosis. Distributed in the US by LUDECA, Inc. • www.ludeca.com 28
Blade and Vanes
MP
A blade or vane generates a signal frequency called
blade pass frequency, fBP:
MP Bn = # of blades or vanes
fBP = Bn ⋅ N
N = rotor speed in rpm
fBPF
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Aerodynamics and Hydraulic Forces
MP MP
There are two basic moving fluid
problems diagnosed with vibration
analysis:
• Turbulence
• Cavitation
Cavitation: Turbulence:
1X fBPF Random 1X
Random
©2011 PRÜFTECHNIK Condition Monitoring – Machinery Fault Diagnosis. Distributed in the US by LUDECA, Inc. • www.ludeca.com 30
Belt Drive Faults
MP MP
Belt transmission a common drive system in
industry consisting of:
• Driver Pulley
• Driven Pulley
MP MP • Belt
Belt frequency:
Ø2
ω2
Ø1 ω1 3,1416ω1φ1
fB =
l
l : belt length
©2011 PRÜFTECHNIK Condition Monitoring – Machinery Fault Diagnosis. Distributed in the US by LUDECA, Inc. • www.ludeca.com 31
Belt Drive Faults
Belt Worn:
fn
Pulley Misalignment:
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Belt Drive Faults
Eccentric Pulleys:
Belt Resonance:
©2011 PRÜFTECHNIK Condition Monitoring – Machinery Fault Diagnosis. Distributed in the US by LUDECA, Inc. • www.ludeca.com 33
Gear Faults
Spur Gear:
Worm Gear:
gear wheel
Driving gear
Gear
Driven gear
gear wheel pair
gear train
Planet Gear:
Bevel Gear:
Ring (cone) Bevel gear
Sun gear
Bevel gear
Planet gear
Carrier
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Gear Faults
Gear Meshing:
Pitch surface
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Gear Faults
MP
fz fz 2⋅fz 3⋅fz 4⋅fz
fn1
z2
z1
MP
fn2
Wear
fz 2⋅fz 3⋅fz
MP MP Detail of X:
X
fz
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Gear Faults
MP
Tooth break-out
MP MP fz and
X Detail of X: harmonics
z1 z2 Sidebands
fz
fn1 fn2
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Gear Faults
fz
Gearwheel being
manufactured
Cutting tool
zM
©2011 PRÜFTECHNIK Condition Monitoring – Machinery Fault Diagnosis. Distributed in the US by LUDECA, Inc. • www.ludeca.com 38
Electrical Motors
• Stator eccentricity
• Eccentric rotor
• Rotor problems
• Loose connections
©2011 PRÜFTECHNIK Condition Monitoring – Machinery Fault Diagnosis. Distributed in the US by LUDECA, Inc. • www.ludeca.com 39
Electrical Motors
Stator Eccentricity:
• Loose iron
• Shorted stator laminations
• Soft foot
MP MP
1X 2X
©2011 PRÜFTECHNIK Condition Monitoring – Machinery Fault Diagnosis. Distributed in the US by LUDECA, Inc. • www.ludeca.com 40
Electrical Motors
Eccentric Rotor:
• Rotor offset
• Misalignment
• Poor base
MP MP
fp 1X 2X
Tslippage
Radial
2⋅fL
t [ms]
fp, 1X, 2X and 2fL signals.
Modulation of the vibration time signal with the slip
1X and 2fL with sidebands at fP. frequency fslip
Radial predominant. Tslip ≈ 2-5 s
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Electrical Motors
Rotor Problems:
Radial
f [Hz]
2. Broken or cracked rotor bars:
1X 2X 3X 4X • 1X and harmonics with sidebands at fP
Radial • High resolution spectrum needed
• Possible beating signal
©2011 PRÜFTECHNIK Condition Monitoring – Machinery Fault Diagnosis. Distributed in the US by LUDECA, Inc. • www.ludeca.com 42
Electrical Motors
Radial
• fbar and 2fbar with 2fL sidebands
• 2fbar can be higher
• 1X and 2X can appear
fn 2f2f
n L • 2fL excessive signal with sidebands at 1/3 fL
Radial • Electrical phase problem
• Correction must be done immediately
©2011 PRÜFTECHNIK Condition Monitoring – Machinery Fault Diagnosis. Distributed in the US by LUDECA, Inc. • www.ludeca.com 43