BG1605-11_Machine Diagnostics Toolbox_Medium.

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Machine Diagnostics Toolbox

BG 1605 – 11

Industrial Solutions
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MACHINE
DIAGNOSTICS TOOLBOX
VIBRATION MEASUREMENT AS A MACHINE HEALTH INDICATOR
Changes in vibration levels measured on the surface of a machine are the result
of changes in internal forces. These forces, and therefore vibration levels,
increase when the condition of the machine deteriorates – due to unbalance,
misalignment, bearing & gear tooth wear. High vibration can also arise from
resonances or structural modifications such as corrosion, structure and foundation
cracks, coupling resonances, etc. Checking machine vibration levels over a period
of time or permanently, as is done in on-line monitoring systems, will indicate
the development of fault conditions (but not the nature of the fault). This
process is called Machine Condition Monitoring.

By using various diagnostic techniques, which also use vibration measurement

as an indicator, the root cause of the deteriorating machine condition can be
established. The Plant Engineer can therefore plan the corrective measures at a In the Oil & Gas industry, machine downtime is very costly
convenient time, and prepare appropriate spare parts. Diagnostic techniques
are extremely effective because they use the information contained in the
machine's vibration signature. The signature is obtained by frequency and time
analysis of the machine vibration signal from a sensor fixed on the surface of
(or inside) the machine. It enables troubleshooting of rotor dynamic problems,
rotating component deterioration as well as structural problems. This process is
called Machine Diagnostics.

This brochure presents a new complete Machine Diagnostics Toolbox that

introduces the vibration analysis hardware, and the software tools, which
enable the Plant Engineer to succeed in diagnosing a wide range of machine
fault types, including those which are not caused by faulty rotating parts.

MACHINE DIAGNOSTICS TOOLBOX

The Machine Diagnostics Toolbox is based on the PULSE Multi-analyzer System
Type 3560. This means that the hardware for acquiring the vibration signals The Power industry often requires multichannel measurements
from various vibration transducers is available in many different versions.
PULSETM System Type 3560 B offers from 1–5 input channels and Type 3560 C
offers 17 input channels. Hardware is available for hundreds of channels.

A portable version of the PULSE System is available in a yellow ruggedized and

weatherproof suitcase, including a Laptop PC. Both the PULSE Front-end and
the Laptop PC are powered from rechargeable batteries.

The PULSE Front-ends accept signals via BNC/BNT connectors from Tacho
Probes, Accelerometers, Velocity Probes, Proximity Probes as well as Direct
Voltage signals available from Condition Monitoring systems. Performing Rotor
Dynamics Analysis is then an easy task, since the Proximity Probe signals can be
obtained from the Condition Monitoring system, using simple BNC-BNC cables.

Additionally, the Machine Diagnostics Toolbox offers a comprehensive range of Direct Voltage available from Condition Monitoring Systems
software tools for diagnosing various machine faults. The inside of this
brochure shows an overview of the different tools and their application. The
modularity of the software and freedom to choose only the desired software
packages allows for tailoring the Machine Diagnostics Toolbox exactly to your
needs, whether it is for oil & gas industry, petrochemical industry, power industry,
cement industry, etc. Always, the software Type 7770 is required as a basis.

All software packages have an easy-to-use, task oriented graphical user interface.
In this way, performing the measurement and analysis is simply done by following
a sequence of tasks.

TYPICAL ACCELEROMETER AND CABLES:

Industrial Accelerometer Type 8341
Magnet for Industrial Accelerometer UA 1281
2-pin MIL-C-5015 to BNC cable (5 m) AO 0608 (various lengths available)
BNC-BNC cable (3 m) AO 0142 (for Direct Voltage input) Brüel & Kjær offers a large range of accelerometers
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MACHINE
DIAGNOSTICS TOOLS
FFT ANALYSIS TYPE 7770, INCLUDES:

– BASEBAND & ZOOM FFT ANALYSIS

The FFT analysis provides the vibration “signature” of the machine, as a vibra-
tion level vs. frequency, also called vibration spectrum. Predominant frequency
components, for example, due to unbalanced rotors, misalignment, bent shaft,
damaged or worn gears, are easily identifiable. FFT Analysis in up to 6400
lines from DC to 25 kHz (up to 200 kHz in certain configurations) is supported
as well as a real-time zoom function enabling very closely spaced frequency
components to be separated and identified.

– SIMULTANEOUS REAL-TIME MULTI-ANALYSIS

Provides data consistency and reduced test time by performing different types
of analysis simultaneously on all input channels. Cepstrum analysis on gearbox

– TACHOMETER & TRIGGER

Facilitates measurement of RPM value obtained from Tacho signals, e.g.,
from a Keyphasor®. All analyzers and measurements can be triggered for
start/stop, e.g., by RPM signal or vibration signal.

– SIGNAL ENHANCEMENT
Using a trigger, unwanted non-periodic components in the time signal and
related spectrum, can be suppressed, e.g., for separation of adjacent
machines or different shafts.

– AUXILIARY PARAMETER LOGGING

Facilitates the input and logging of process parameters, like temperature,
pressure and load for correlation with vibration inputs.

– CEPSTRUM ANALYSIS Envelope analysis showing inner ring defect on ball bearing
Especially useful for identifying and quantifying a series of “harmonics”
or “sidebands” in the vibration spectrum originating from gearbox shafts
and gears, and from rolling element bearings – and thus identifying machine
faults in these sources. Allows separation of transmission path effects from
excitation forces (liftered spectrum). The Cepstrum analysis may also be used
for variable-speed machines, by the additional use of Order Analysis Type 7702

– FREQUENCY RESPONSE FUNCTION (FRF)

The level of vibration measured on the surface of a machine is a function of
both the excitation forces and the mobility (structural resonances) of the
machine. The FRF identifies the structural resonances, thus avoiding faulty
diagnosis and changing of good rotating parts.

ENVELOPE ANALYSIS TYPE 7773

Faults in rolling element bearings, gear-teeth, and turbine blades are often Display different analyses simultaneously
low-energy signals, that are difficult to detect until they become severe.
Envelope analysis enables detection of these signals, and gives information
about the precise fault frequencies and, in the case of reciprocating machines,
gives the precise location in the machine rotation cycle – and therefore, the
probable cause, at a very early stage of the fault.

Recording & editing of time wave files

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BASEBAND & ZOOM FFT ANALYSIS

MULTI-ANALYSIS

TACHOMETER

TRIGGER

SIGNAL ENHANCEMENT

AUXILIARY PARAMETER LOGGING

CEPSTRUM ANALYSIS DATA RECORDER TYPE 7708 TIME CAPTURE TYPE 7705 TIM
Facilitates data recording of the vibration For analysis of transients and non- Incl
time signal over a period of time, to the stationary signals Time Capture facilitates sele
PC hard disk, while simultaneously per- selection of a short time signal around a tim
forming measurements. The recording transient and transforming it to the fre- the
enables detailed examination of the quency domain using Short Time Fourier Esp
vibration data, in the office, for post-pro- Transform. The latter is very efficient, for spe
FREQUENCY RESPONSE FUNCTION cessing using all software tools provided example, for examining vibration signals fere
in the Machine Diagnostics Toolbox. Data from reciprocating machines. and
recording is essential when diagnosing wh
faults on non-stationary signals such as unk
cyclic machines and run-up & run-down of
test. Start and stop of the Data Recorder allo
can be controlled by an internal or exter- find
ENVELOPE ANALYSIS nal trigger (pre- and post-trigger avail-
able), e.g., a tacho or vibration signal.

Brüel & Kjær

 BG1605-11_Machine Diagnostics Toolbox_Medium.qxp
TIME FILE MANAGEMENT TYPE 7789
non- Includes functionality to simplify the
tates selection, viewing (and listening to) of
nd a time data recordings, to help choose
fre- the most interesting part for analysis.
urier Especially valuable for data from variable
t, for speed and cyclic machines, where dif-
gnals ferent parts of the cycle can be identified
and analysed separately. It is essential
where random phenomena occur at
unknown times as it allows correlation
of all input signals with the event and
allows examining prior operation, to
find the origin of the event.
www.bksv.com
18-04-2005 09:28 Page 7
ORDER ANALYSIS
RUN UP/RUN DOWN
AUTOTRACKING
ROTOR DYNAMICS ANALYSIS
ORBIT PLOT
DC
SHAFT CENTRE LINE PLOT
DATA MANAGER TYPE 7767 RIGID BALANCING
When measuring on many different
machines, the vibration data gathered
can quickly become cumbersome. With
PULSE Data Manager, measurement data
can be saved together with associated
labels and meta-data. Data searching
and retrieval is intuitive allowing easy OPERATING DEFLECTION SHAPES
display, comparison, and reporting.
Allows easy comparison of data from
several measurement points, machines
and operating conditions. Data Manager
includes a Microsoft® SQL database and
a Reporting Tool using Microsoft® Word.
OPERATIONAL MODAL ANALYSIS
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DIAGNOSTICS TOOLS FOR COMMON

MACHINE FAULTS
Common Machine Faults

Journal Oil Film Rolling Electric Cyclic

Bearings Geartooth Turbine Blade
Rotor Mis- Bearing Instability Element Motor- Machinery Critical Loose Structural
Rotor rub Loose Wear Blade Wear Cavitation, Software Tools
Unbalance alignment Wear & in Journal Bearing specific Fault Speed Foundations Resonances
in Housings & Cracks & Cracks Turbulence
Run-out Bearings Defects Rotor Faults Diagnosis

✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ Baseband FFT
Analysis

✓ ✓ ✓ ✓ ✓ Zoom FFT
Analysis

✓ ✓ ✓ ✓ Envelope
Analysis

✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ Signal
Enhancement

✓ ✓ ✓ ✓ ✓ Cepstrum Analysis

✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ Order Analysis

✓ Frequency Response
Function

✓ ✓ ✓ ✓ ✓ Orbit Plot

✓ ✓ ✓ ✓ ✓ Shaft Centre
Line Plot

✓ Two-Plane
Balancing

Displacement
✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ Velocity
Acceleration

RMS, Peak,
✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ Peak-to-
Peak Level

✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ Tolerance
Curves

Analysis
✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ Bandwidth &
Resolution

✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ Multi-Analysis

✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ Tachometer
& Trigger

✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ Auxilliary Parameter
Logging

✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ Time Data Recorder

✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ Time Data Editing

✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ Data Manager

✓ ✓ Operating Deflection
Shapes

✓ ✓ Operational Modal
Analysis
BG1605-11_Machine Diagnostics Toolbox_Medium.qxp
MACHINE
DIAGNOSTICS TOOLS
Order analysis seperating orders from structural resonances
Orbit plot – Showing vibratory displacement of the shaft
Two-plane Balancing Consultant Type 7790 A
Geometry model of a machine for Operating Deflection Shapes
18-04-2005 09:28 Page 8
ORDER ANALYSIS TYPE 7702
Order analysis is essential when examining vibration from machines with non-
constant speed (i.e., non-stationary conditions). A tachometer probe signal
ensures that the analyzer follows rpm changes in the machine. Order analysis allows
identification of critical speeds during run-up/down, for analysis of variable speed
machines and for separation of rotationally related components from structural-
ly related components. If a tacho probe signal is not available, the
AutotrackingTM functionality allows extracting a tacho signal directly from a
vibration signal. Order Analysis Type 7702 provides all the tools necessary to
clearly identify vibration components at multiples of the rotating speed
(“orders” or “harmonics”), especially useful for high order harmonics.
ROTOR DYNAMICS ANALYSIS WT 9695
The Rotor Dynamics Analysis software is a set of specific tools for fault diagnosis on
machines with journal bearings and fitted with 2 displacement probes (proximity
o
probes) at 90 angular spacing, and a tachometer probe (Keyphasor®).
– ORBIT PLOT
The Orbit plot shows an Y vs. X plot of vibratory displacement of the shaft,
based on the AC signals from the Y and X proximity probes. The shape of
the Orbit plot and the position of the tachometer probe “dot” indicate
characteristic faults such as unbalance, misalignment, and oil film instability.
The Orbit can be unfiltered or filtered for selected order 1X, 2X.
– SHAFT CENTRE LINE PLOT
Shows the position of the shaft relative to the inside of the bearing journal
by measuring the average value of the distance (gap) between the probe
tips and the shaft surface. Identifies abnormal shaft position caused by lubri-
cation problems, shaft misalignment, and indicates risk of friction wear (rubbing).
Tags in the Shaft Centre Line Plot shows parameters of either RPM, Time, or
Process parameters such as load, temperature, etc.
RIGID BALANCING
TWO-PLANE BALANCING CONSULTANT TYPE 7790 A
Unbalance of rigid rotors is one of the most common faults encountered in
machinery. The Balancing Consultant supports rigid single-plane and two-plane
balancing as either in-situ (field) balancing, where the rotor is balanced in its own
bearings and supporting structure, or balancing using balancing machines.
OPERATING DEFLECTION SHAPES (ODS)
ODS TEST CONSULTANT TYPE 7765 AND ME’SCOPETM ODS TYPE 7754 G
ODS is used for visualization of the vibration pattern of a structure under given
operating conditions. Vibration measurements are performed at different points
and directions (DOFs) on the structure and the vibration pattern can be shown
as an animated geometry model of the structure, or listed in a table. ODS is
very useful to detect location of cracks, loose foundations and other weaknesses.
OPERATIONAL MODAL ANALYSIS (OMA)
MODAL TEST CONSULTANTTM TYPE 7753 AND OMA TYPE 7760
OMA is used for determination of the modal parameters (natural frequency,
damping and mode shapes) under true operating conditions by only measuring
the responses. Where ODS gives the actual vibration pattern, OMA gives the
true mode shapes of the structure. OMA is useful for finding the “source” of
the problem and not only the symptoms.
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Service and Technical Support

To ensure that you receive the full benefit
of our equipment, Brüel & Kjær offers
worldwide service and support including
accredited calibration, on-site traceable
calibration, installation, software mainte-
nance and upgrade contracts, product
training, and application courses.

Publications
We offer a comprehensive range of high-
quality publications that includes user
manuals, product data sheets, brochures,
application notes, technical reviews, cata-
logues, and the Brüel & Kjær Magazine.

Contact Us
If you would like any further information,
please contact your local Brüel & Kjær sales
representative.

Internet
We’re never further away than
www.bksv.com

BG 1605 – 11

HEADQUARTERS: DK-2850 Nærum · Denmark · Telephone: +45 4580 0500

Fax: +45 4580 1405 · www.bksv.com · info@bksv.com

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