Machinery Vibration

Machinery Vibration Analysis and Predictive Maintenance 23/08/2013
Practical Machinery
Vibration Analysis and
Predictive Maintenance
By Steve Mackay
Dean of Engineering
Engineering Institute of Technology
www.eit.edu.au
EIT Micro-Course Series

• Every two weeks we present a 35
to 45 minute interactive course
• Practical, useful with Q & A
throughout
• PID loop Tuning / Arc Flash
Protection, Functional Safety,
Troubleshooting conveyors
presented so far
• Upcoming:
– Electrical Troubleshooting and
much much more…..
• Go to http://www.eit.edu.au/free-
courses
• You get the recording and slides
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IDC Technologies and EIT

1
Objectives
• Give some background to vibration measurement

• Give some suggested techniques
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Maintenance Philosophies
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2
Vibration in everyday life
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Useful Vibration
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3
Vibration Monitoring
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4
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5
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6
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Vibration Basics
Any external force has to overcome structure’s

properties:
- Mass
- Stiffness
- Damping
A force cause vibration!!!
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7
Vibration Basics
Vibration can be described in terms of:

- Acceleration
- Velocity
- Displacement
Single degree of freedom system:
- Forced vibration response
- Free vibration response
- Resonance is free vibration
Frequency is number of vibration cycles / time!
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Vibration Basics
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8
System Response
10N
2g
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Nature of Vibration - SHM
• X = Xo sin ω t
• X = Disp. at instant t
• Xo = Maximum disp.
ω = 2 .π. f (rad/s)
• f = frequency (Hz)
• t = time (seconds)
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9
Wave Terminology
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Wave Terminology - Phase
• A time lag of T is a phase angle of 360º.

• A time lag of T/4 will be a phase angle of 90º.
The two waves are out of phase by 90º !
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10
A Fast Fourier Transform
Also called the Frequency

Domain or Vibration Spectrum
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Harmonics
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11
Frequency and Time

Domains
• FFT is the
Frequency Domain.
• Time Waveform is
the Time Domain.
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Frequency Analysis
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12
Why do a Frequency Analysis?
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Overall Amplitude
• It is the total
vibration amplitude
over a wide range of
frequencies.
• Acceleration,
Velocity, or
Displacement.
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13
Which to choose?
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“Real world” vibration levels
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14
Vibration Terminology
• Displacement [peak-peak]
• Velocity [peak]
• Velocity [rms]
– Velocity rms tends to provide the energy
content in the vibration, whereas the
Velocity peak depicts more of the intensity
of vibration.
• Acceleration - peak
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Machinery Fault Diagnosis
• Vibration analysis is used to monitor the state of a

machine.
• Detailed analyses can be made concerning the
health of the machine and any faults, which may
be arising or may have already arisen.
• The need for higher reliability and availability of
critical machinery forces the use of this technique
of PdM.
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15
Common Machinery Faults

• Unbalance • Electrical faults
• Bent shaft • Oil whip / whirl
• Eccentricity • Cavitation
• Misalignment • Shaft cracks
• Looseness • Rotor rubs
• Belt drive problems • Resonance
• Gear defects • Hydraulic + aerodynamic
• Bearing defects forces
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Unbalance - Static
• Amplitude due to
unbalance will vary
with the square of
speed.
• The FFT will show
1 × rpm frequency of
vibration.
• It will be predominant.
• Phase difference is as
shown
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16
Unbalance - Couple
• Amplitude varies with
square of speed.
• Predominant 1 × peak.
• May cause high axial
along with radial
vibrations.
• Phase difference is
180º on shaft ends in
both planes.
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Unbalance - Overhung
Rotors
• Amplitude varies with
square of speed.
• Predominant 1× peak.
• May cause high axial
along with high radial
vibrations.
• Axial plane phase
difference is 0º. Radial
direction phase is
unsteady.
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17
Bent Shaft
• Bend near centre:
1× is predominant.
• Bend at ends: 2× is
predominant.
• No phase difference
in radial direction at
one location.
• 180º phase
difference in axial
plane.
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Misalignment
• After unbalance, misalignment is the major cause

for high vibrations.
• Two kinds of misalignment:
– Angular - shaft ends meet an angle.
– Parallel - shaft ends are parallel but have an offset.
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18
Angular Misalignment
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Angular Misalignment
• Predominant peak is
1×.
• 1×, 2 ×, 3 × may be
present.
• High axial vibration
with 1 × and 2×.
• Axial phase difference
across the coupling is
180º.
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19
Bent Shaft - Angular

Misalignment
• Difference between
angular
misalignment and a
bent shaft is
differentiated only
by phase difference.
• In misalignment,
phase difference is
180º across the
coupling.
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Parallel Misalignment
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20
• The predominant
peak is at 2×.
• Vibrations in radial
direction are higher
than in the axial
direction.
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• Phase difference in
radial direction
across the coupling
is 180º.
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21
Misaligned Bearing
• Cocked bearing
show high axial
vibrations
• Opposite ends have
an axial plane phase
difference of 180º.
• FFT may show
peaks of 1×, 2× and
3×.
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Misalignment - Orbits
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22
Mechanical Looseness
• Internal assembly looseness:
– Bearing liner in its cap.
– Sleeve or rolling element bearing.
– Impeller on a shaft.
• Looseness at machine to base plate interface:
– Loose bolts.
– Cracks in the frame structure or bearing pedestal.
• Structure looseness:
– Weakness of machine feet, baseplate or foundation.
– Loose hold-down bolts, distortion of frame or base.
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Internal Looseness
• Phase is unstable.
• Radial vibrations
taken at 30º. Will
see different
spectrums for each
(directional).
• FFT will show
harmonics of × or
even ×.
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23
Looseness at Machine to Base

Plate interface
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Structure Looseness
• Measure each bolt, one at a time.
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24
Resonance
• Every body has a resonance frequency.

• Frequency is dependant on mass, stiffness and
damping.
• Forced and free vibrations (e.g. ringing of bell).
• Resonance is free vibrations.
• Bump test is simple technique to find resonant
frequency of stationary mass or system.
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Bump Test
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25
Thank You For Your Interest

If you are interested in further training, please visit:
IDC Technologies Short Courses:

Two-day practical courses available to the public:
http://idc-online.com/workshops
IDC Technologies Conferences:

http://idc-online.com/conferences-main
The Engineering Institute of Technologies

Online Certificate and
Advanced Diploma programs:
www.eit.edu.au
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26

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Machinery Vibration Analysis and Predictive Maintenance 23/08/2013

EIT Micro-Course Series

IDC Technologies and EIT

• Give some background to vibration measurement

IDC Technologies and EIT

Vibration in everyday life

IDC Technologies and EIT

IDC Technologies and EIT

IDC Technologies and EIT

IDC Technologies and EIT

Any external force has to overcome structure’s

IDC Technologies and EIT

Vibration can be described in terms of:

Frequency is number of vibration cycles / time!

IDC Technologies and EIT

Nature of Vibration - SHM

IDC Technologies and EIT

Wave Terminology - Phase

• A time lag of T is a phase angle of 360º.

The two waves are out of phase by 90º !

IDC Technologies and EIT

A Fast Fourier Transform

Also called the Frequency

IDC Technologies and EIT

Frequency and Time

IDC Technologies and EIT

Why do a Frequency Analysis?

IDC Technologies and EIT

“Real world” vibration levels

IDC Technologies and EIT

Machinery Fault Diagnosis

• Vibration analysis is used to monitor the state of a

IDC Technologies and EIT

Common Machinery Faults

IDC Technologies and EIT

IDC Technologies and EIT

• After unbalance, misalignment is the major cause

IDC Technologies and EIT

IDC Technologies and EIT

Bent Shaft - Angular

IDC Technologies and EIT

IDC Technologies and EIT

IDC Technologies and EIT

IDC Technologies and EIT

Looseness at Machine to Base

• Measure each bolt, one at a time.

IDC Technologies and EIT

• Every body has a resonance frequency.

IDC Technologies and EIT

Thank You For Your Interest

IDC Technologies Short Courses:

IDC Technologies Conferences:

The Engineering Institute of Technologies

IDC Technologies and EIT

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