TYPESOFFAULTSI

NMACHI
NERY

I
ntr
oduct
ion

Machi
nef
aul
tdi
agnosi
sisaf
iel
dofMechani
cal
Engi
neer
ingconcer
nedwi
th
f
indi
ngf
aul
tsar
isi
ngi
nmachi
nes.Apar
ti
cul
arl
ywel
ldev
elopedpar
tofi
tappl
i
es
speci
fi
cal
l
ytor
otat
ingmachi
ner
y,oneoft
hemostcommont
ypesencount
ered.
Toi
dent
if
ythemostpr
obabl
efaul
tsl
eadi
ngt
ofai
l
ure,
manymet
hodsar
eused
f
ordat
acol
l
ect
ion,
incl
udi
ngv
ibr
ati
onmoni
tor
ing,
ther
mal
imagi
ng,
oil
par
ti
cle
anal
ysi
s,et
c.Thent
hesedat
aar
epr
ocessedut
il
izi
ngmet
hodsl
i
kespect
ral
anal
ysi
s,wav
eletanal
ysi
s,wav
efor
m anal
ysi
s(i
nthet
imedomai
n,because
spect
ral
anal
ysi
susual
l
yconcer
nsonl
yfr
equencydi
str
ibut
ionandnotphase
i
nfor
mat
ion)andot
her
s.Ther
esul
tsoft
hisanal
ysi
sar
eusedi
nar
ootcause
f
ail
ureanal
ysi
sinor
dert
odet
ermi
net
heor
igi
nal
causeoft
hef
aul
t.Forexampl
e,
i
fabear
ingf
aul
tisdi
agnosed,
theni
tisl
i
kel
ythatt
hebear
ingwasnoti
tsel
f
damagedati
nst
all
ati
on,
butr
atherast
heconsequenceofanot
heri
nst
all
ati
on
er
ror(
e.g.
,mi
sal
i
gnment
)whi
cht
henl
edt
obear
ingdamage.Di
agnosi
ngt
he
bear
ing'
sdamagedst
atei
snotenoughf
orpr
eci
sionmai
ntenancepur
poses.The
r
ootcauseneedst
obei
dent
if
iedandr
emedi
ed.I
fthi
sisnotdone,
the
r
epl
acementbear
ingwi
l
lsoonwearoutf
ort
hesamer
easonandt
hemachi
newi
l
l
suf
fermor
edamage,
remai
ningdanger
ous.Ofcour
se,
thecausemayal
sobe
v
isi
bleasar
esul
toft
hespect
ral
anal
ysi
sunder
takenatt
hedat
a-col
l
ect
ion
st
age,
butt
hismaynotal
way
sbet
hecase

Someofmachi
ner
yfaul
ts

1.Mechani
cal
Looseness
2.unbal
ance
3. Mi
sal
i
gnment
4.Bel
tdr
ivePr
obl
ems
5.Bear
ingDef
ect
s
6.Bentshaf
t
7.Cr
it
ical
Speed
8. GearDef
ect
s
 9.Eccent
ri
cit
y
10.Resonance
11.Oi
lwhi
p/whi
rl
12.El
ect
ri
cal
Faul
ts
13.Rot
orCr
ack

Nowwewi
l
ldi
scusssomeoft
hisf
aul
tsandi
t'
sreasons
1.Mechani
cal
looseness
I
fweconsi
deranyr
otat
ingmachi
ne,
mechani
cal
loosenesscanoccuratt
hree
l
ocat
ions:
 I
nter
nal
assembl
ylooseness
 Loosenessatmachi
net
obasepl
atei
nter
face
 St
ruct
urel
ooseness.

1.
1Int
ernal
Assembl
yLooseness
Thi
scat
egor
yofl
oosenesscoul
dbebet
weenabear
ingl
i
neri
nit
scap,
a
sl
eev
eorr
oll
i
ngel
ementbear
ing,
orani
mpel
l
eronashaf
t.I
tisnor
mal
l
ycaused
byani
mpr
operf
itbet
weencomponentpar
ts,
whi
chwi
l
lpr
oducemanyhar
moni
cs
i
ntheFFTduet
othenonl
i
nearr
esponseoft
hel
oosepar
tst
otheexci
ti
ngf
orces
f
rom t
her
otor
.At
runcat
ionoft
het
imewav
efor
m occur
s,causi
nghar
moni
cs.The
phasei
sof
tenunst
abl
eandcanv
arybr
oadl
yfr
om onemeasur
ementt
othenext
,
par
ti
cul
arl
yift
her
otoral
ter
sit
sposi
ti
onont
heshaf
tfr
om onest
art
-upt
othe
next
.
Mechani
cal
loosenessi
sof
tenhi
ghl
ydi
rect
ional
andmaycausenot
iceabl
ydi
ff
erent
r
eadi
ngswhent
heyar
etakenat30°i
ncr
ement
sint
her
adi
aldi
rect
ional
lar
oundt
he
bear
inghousi
ng.Al
sonot
ethatl
oosenesswi
l
lof
tencausesub-
har
moni
cmul
ti
plesat
exact
ly½×or⅓×r
pm (
e.g.½×,
1½×,
2½×andf
urt
her
)

l
oosei
nter
nal
assembl
ygr
aph
1.
2Loosenessbet
weenmachi
nest
obasepl
ate

Thi
sprobl
em i
sassoci
atedwi
thl
oosepi
l
low-
blockbol
ts,
cracksi
nthef
rame
st
ruct
ure
orthebear
ingpedest
al.Fi
gur
es.
..and.
..
.makeitev
identhowhigherharmoni
csar
e
generat
edduetotherocki
ngmotionofthepi
l
lowblockwithl
oosebolts.

Mechani
cal
loosenessgr
aphs
1.
3St
ruct
urel
ooseness

Thi
sty
peofl
oosenessi
scausedbyst
ruct
ural
loosenessorweaknessesi
nthe
machi
ne’
s
feet
,basepl
ateorf
oundat
ion.I
tcanal
sobecausedbydet
eri
orat
edgr
out
ing,
loose
hold
downbol tsatthebaseanddi stort
ionoftheframeorbase( knownas‘ softfoot
’)
(Figur e1.16)
.Phaseanalysismayr evealapproximatel
y180°phaseshi f
tbetween
verticalmeasur ementsont hemachi ne’
sfoot,baseplateandbaseitself(
Figure
1.17) .Whent hesoftf
ootconditionissuspected,aneasytesttoconfir
mf oriti
st o
l
ooseneachbol t
,oneatat ime,andseeifthisbringsaboutsigni
fi
cantchangesi nthe
vibration.Int
hiscase,i
tmi ghtbenecessarytor e-machi
nethebaseori nstal
lshi
ms
toel i
mi natethedi
stor
tionwhent hemount ingboltsareti
ghtenedagain.

2.Massunbal
ance(
For
ceunbal
ance)
pr esentandnor mallydomi natesspectrum.Ampli
tudevari
eswi thsquareof
speedbel owf i
rstrotorcri
ti
calspeed.Maycausehi ghaxialvi
brationasi ncreasi
ng
.Cor r
ecti
onr equiresplacementofbal anceweight
sinatleast2pl aneswellasradial
.
180°phasedi f
ferenceshoul dexistbetweenOB&I Bhori
zontals,as. Notethatapprox
IBv erti
cals.Al
so, approx.a90°di ff
erencebet
weent he&wellasbet weenOB
readingsoneachbear ingusual l
yoccurs(±30°
)hori
zontal&ver t
icalphase

3.Coupl
eunbal
ance
Coupl
eUnbal
ancer
esul
tsi
n180°out
-of
-phasemot
iononsameshaf
t.1XRPM
al
ways

presentandnor mallydominatesspect r
um.Ampl i
tudev ari
eswi thsquareof
i
ncreasingspeedbel owf i
rstr
otorcr i
ti
calspeed.Maycausehi ghaxialvibr
ationas
well asradi
al.Corr
ecti
onrequiresplacementofbal ancewei ghtsinatleast2pl anes.
Notet hatapprox.180°phasedi f
ferenceshouldexistbetweenOB&I Bhorizontals,
as
well asbetweenOB&I Bverti
cals.Also,appr
ox.a90°di ff
erencebet weenthe
horizontal&verti
calphasereadingsoneachbear ingusuallyoccur s(±30°)

3.Dy
nami
cUnbal
ance
Dynami cUnbalanceisthedomi nanttypeofunbal ancefoundandi sacombi nationof
bothforceandcoupl eunbalance.1XRPM domi natesthespect r
um, andtrul
y
requi
res2pl anecorrecti
on.Here,t
her adial
phasedi ff
erencebetweenout boardand
i
nboar dbear i
ngscanr angeanywheref rom 0°t
o180° .Howev er,t
hehorizontalphase
dif
ferenceshouldcloselymatchthev ert
icalphasedi f
fer
ence, whencompar i
ng
outboardandi nboardbeari
ngmeasur ement s(±30°).Secondaril
y,i
funbalance
predominates,roughlya90°phasedi f
ferenceusual l
yresul
tsbetweent hehor i
zontal
andv ert
icalr
eadingsoneachbear ing(±40°)

4.Ov
erhungr
otorunbal
ance

Over
hungRotorUnbal
ancecauseshi
gh1XRPM inbothAxial
andRadialdi
rect
ions.
Axi
alreadi
ngst
endtobein-
phasewhereasr
adi
alphasereadi
ngsmightbeunsteady
Howev er,t
hehorizontal
phasedi f
fer
enceswillusuall
ymat cht
hev er
ti
calphase
di
fferencesontheunbal ancedrot
or(±30°)
,Overhungr ot
orshavebothforceand
coupleunbalance,eachofwhi chwil
ll
ikel
yrequir
ecor r
ecti
on.Thus,cor
recti
on
weightswillmostalwayshav etobeplacedin2pl anestocount
eractbothforceand
coupleunbalance.

5.
Misal
i
gnment
5.
1Angul
armi
sal
i
gnment

AngularMi sal
ignmentischar act
erizedbyhi ghaxialvi
br at
ion,180°out
-of-phase
acr
osst hecoupl i
ng.Typi cal
lywi
llhav ehighaxialvi
brationwithboth1Xand2XRPM.
Howev er,notunusualforei t
her1X, 2Xor3Xt odominat e,
Thesesy mptomsmayal so
i
ndicatecouplingproblemsaswel l
.Sev ereangularmi sali
gnmentmayexci temany
1XRPM har monics.UnlikeMechani calLoosenessTy pe3, thesemulti
pleharmonics
donott ypical
l
yhav ear aisednoisef l
ooront hespectra.
5.
2par
all
elMi
sal
i
gnment
Off
setMi
sal
i
gnmenthassi
mil
arv
ibr
ati
onsy
mpt
omst
oAngul
ar,
butshowshi
gh
r
adial

vi
brati
onwhi chappr oaches180°out -
of -
phaseacr osscoupl i
ng.2Xof tenlargerthan
1X,butit shei
ghtrelati
veto1Xi softendi ctat
edbycoupl i
ngtypeandconst ruct
ion.
Whenei therAngularorRadialMisali
gnmentbecomessev ere,theycangener ate
ei
therhighampl it
udepeaksatmuchhi gherhar monics( 4X-
8X), orev
enawhol e
seri
esofhi ghfrequencyharmonicssi milarinappear ancetomechani callooseness.
Coupli
ngt ypeandmat er
ialwi
lloft
engr eat l
yinfl
uencet heenti
respect rum when
misali
gnmenti ssevere.Doesnott ypicall
yhav eraisednoisefloor.
5.
3Mi
sal
i
gnedBear
ingcockedonshaf
t

CockedBeari
ngwi l
lgener
ateconsi
derabl
eaxi
al v
ibrat
ion,Wil
lcauseTwisti
ngMot i
on
wit
happroximatel
y180°phaseshif
ttoptobottom and/orsi
detosideasmeasur ed
i
naxialdir
ecti
ononsamebear i
nghousing.At
tempt stoali
gncoupli
ngorbalancethe
rot
orwill
notall
evi
ateprobl
em.Beari
ngusuall
ymustber emovedandcorrectl
y
i
nstal
led.

7.Gear
ingdef
ect
s
I
nourpr
ojectt
hemosti
mpor
tantdef
ect
sar
egear
ingboxdef
ectsowewi
l
l
speci
all
ytr
ytocov
ert
hem.

7.
1Usi
ngVi
brat
ionAnal
ysi
stoDet
ectEar
lyFai
l
ureofBear
ings

7.
1.1Sour
ceOfVi
brat
ion
7.
1.2Var
iabl
eCompl
i
ance
7.
1.3Geomet
ri
cal
Imper
fect
ions