Engineering Institute of Technology (EIT) 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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 Engineering Institute of Technology (EIT) 23/08/2013

Objectives

• Give some background to vibration measurement

• Give some suggested techniques

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Maintenance Philosophies

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 Engineering Institute of Technology (EIT) 23/08/2013

Vibration in everyday life

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Useful Vibration

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Vibration Monitoring

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Vibration Monitoring

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 Engineering Institute of Technology (EIT) 23/08/2013

Vibration Monitoring

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Vibration Monitoring

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Vibration Monitoring

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Vibration Monitoring

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 Engineering Institute of Technology (EIT) 23/08/2013

Vibration Monitoring

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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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 Engineering Institute of Technology (EIT) 23/08/2013

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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 Engineering Institute of Technology (EIT) 23/08/2013

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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 Engineering Institute of Technology (EIT) 23/08/2013

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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 Engineering Institute of Technology (EIT) 23/08/2013

A Fast Fourier Transform

Also called the Frequency

Domain or Vibration Spectrum
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Harmonics

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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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 Engineering Institute of Technology (EIT) 23/08/2013

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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 Engineering Institute of Technology (EIT) 23/08/2013

Which to choose?

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“Real world” vibration levels

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 Engineering Institute of Technology (EIT) 23/08/2013

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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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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 Engineering Institute of Technology (EIT) 23/08/2013

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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 Engineering Institute of Technology (EIT) 23/08/2013

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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 Engineering Institute of Technology (EIT) 23/08/2013

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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 Engineering Institute of Technology (EIT) 23/08/2013

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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 Engineering Institute of Technology (EIT) 23/08/2013

Parallel Misalignment

• The predominant
peak is at 2×.
• Vibrations in radial
direction are higher
than in the axial
direction.

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Parallel Misalignment

• Phase difference in
radial direction
across the coupling
is 180º.

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 Engineering Institute of Technology (EIT) 23/08/2013

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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 Engineering Institute of Technology (EIT) 23/08/2013

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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 Engineering Institute of Technology (EIT) 23/08/2013

Looseness at Machine to Base

Plate interface

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Structure Looseness

• Measure each bolt, one at a time.

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 Engineering Institute of Technology (EIT) 23/08/2013

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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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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