Basic Training Program

On
Vibration Analysis
What Is Vibration?
It is the response of a
system to an internal or
external force which causes
the system to oscillate.
 ISO 10816- VIBRATION STANDARDS
Class I :- Machines may be separated drive and driven, or coupled units .Comprising operating
machinery up to approximately 15kW(Approx 20hp).

Class II :- Machinery electrical motors 15kW(20hp) to 75kW(100hp), without special

foundations, or Rigidly mounted engines or machines up to 300kW (400hp)
mounted on special foundations

Class III :- Large rotating assemblies mounted on rigid and heavy foundations.
Class IV :- Large rotating assemblies mounted on soft foundations (i.e., turbine
generators and gas turbines greater than 10MW (approx. 13500hp)Output.
 Vibration Characteristics

Frequency - What is vibrating?

Source of the vibration. How many times oscillation is occurring for
a given time period?
Units: CPS(Hz), CPM.

Amplitude - How much is it vibrating?

Size (severity) of the problem. It is the magnitude of vibration signal.
Units: Micron, MM/Sec, M/Sec2

Phase Angle - How is it vibrating?

Cause of the vibration.
 Measurement

Frequency :- 60 RPM
= 1 Rev / s
= 1 Hz

Amplitude :- 1. Displacement : Total distance traveled by the mass.

Stress Indicator / Distance , Unit : Microns
2. Velocity : Rate of change of displacement. It is the
measure of the speed at which the mass is
vibrating during its oscillation.
Fatigue Indicator , Speed ,
Unit : MM/Sec
3. Acceleration : It is the rate of change of velocity. The
greater the rate of change of velocity the greater
the forces on the machines. Force Indicator
Unit : M/Sec2, Inch/sec2
 Scales Of Amplitude

Period, T
Unit Circle

RMS
0
0 to Peak

Peak-to-Peak

Velocity -RMS
Displacement -Peak-Peak
Acceleration -0-Peak
Direction of measurement

Vertic
al

Horizo
ntal

Axi
al
 Steps of analyze

1. Evaluate overall vibration reading of the entire machine.

(a) Identify 1x RPM peak.
(b) Locate highest amplitude.
(c) What is the direction of the highest amplitude?
(d) What is the frequency of the highest amplitude?
2. See the values of Shock pulse (bearing noise).
3. See the trend - in case of sudden increase the problem severity increases.
4. Analyze the frequency for possible defects.
5. Analyze the phase readings for confirmation if necessary.
 Detection By Vibration Analysis
1.Unbalance (Static, Couple, Quasi-Static),

2. Misalignment Angular, Parallel, Combination)

3. Eccentric Rotor, Bent Shaft

4. Mechanical Looseness, Structural Weakness, Soft Foot

5. Resonance

6. Mechanical Rubbing

7. Problems of Belt Driven Machines

8. Bearing Defects (Inner race, Outer race, Cage, Rolling Elements).

9. Gear Problems (Tooth wear, Tooth load, Gear eccentricity, Gear misalignment,
Cracked Or Broken Tooth etc..)

10.Electrical Problems of AC & DC Motor ( Variable Air Gap, Rotor Bar Defect)
 Cause of vibration
Direction Frequency Phase readings Problem cause  
High vibration in H & V
1 x rpm 90 deg difference in H & V Unbalance Simply supported fans
direction

High vibration in axial along

1 x rpm 90 deg difference in H & V Unbalance On over hang rotor
with H & V direction

180 deg difference in between axial

High vibration in axial with
1 x rpm direction at the bearing location Shaft bend bend of the center of shaft
H & V direction
across the end.

High vibration in axial

1 ,2 X rpm 180 deg phase shift in all direction Misalignment
direction Combination

High vibration in V direction 1 ,2 X rpm 180 deg phase shift between H & V Mechanical looseness
Bolt loosed, cracks, grouting

High vibration in axial 1 ,2 X rpm & 10

  Bearing defects Looseness.
direction to 15 rpm harmonics.

High vibration in axial 1 X rpm & 180 deg phase shift between H & V,
Bearing defects Improper fit with housing.
direction 15 to 18 rpm harmonics. Temperature high.

1 x rpm & gear natural

High vibration in H & V Tooth cracked / broken & heavy
frequency with the gear   Gear Problem
direction noise.
rpm side bends

High vibration in axial along 1 x GMF , 2 x GMF ,

  Gear Problem Gears miss alignment.
with H & V direction 3 x GMF
 Unbalance
Cause of unbalance :- Uneven distribution of mass of rotor.
Dust accumulation on fan rotors.
Uneven erosion and corrosion of Impellers.
Missing balance weights.
Type of unbalance :- Static Unbalance
Dynamic Unbalance
Detection:- Highest horizontal vibration
Amplitude increases as square of speed.
Dominant frequency at 1x rpm
Horizontal readings reflect in vertical direction also.
 Bent Shaft
Diagnosis:
1. High 1X axial and high 1X radial if bent is near the center.
2. High 2X axial and high 2X radial if bent is near the coupling.
3. Amplitude of 1X & 2X rpm will be steady.
4. SPM readings also high.
5. High bearing temperature.
MECHANICAL LOOSENESS
 Misalignment
Cause of misalignment :- Thermal expansion - Most machines align cold.
Machine vibrations.
Forces transmitted to the machine by pipe or support structure.
Soft foot.
Direct coupled machined are not properly aligned.

Types of misalignment :-
1. Off set

2. Angular

3. Skew - Combination of
offset & angular
 Bearings
What do the bearing frequencies mean?
If:
FTF = Fundamental Train Frequency •FTF = 0.381 * RPM
BSF = Ball Spin Frequency •BSF = 1.981 * RPM
BPFO = Ball Pass Frequency Outer race •BPFO = 3.047 * RPM
BPFI = Ball Pass Frequency Inner race •BPFI = 4.952 * RPM
 Gear box

Z1
RPM1

RPM2

Z2

GMF (Gear Mesh Frequency)

Z1 .RPM1 = Z2 .RPM2
where Z = no. of teeth and RPM shaft speed

Mating gears produce only one ‘Gear Mesh Frequency’

 Gear box defects :- Tooth wear
Gear eccentricity & backlash
Gear misalignment
Cracked or broken tooth
Spur gear produce vibration in radial direction and helical gear produce in radial & axial
directions. Sideband spacing reveals the defective gear or pinion. All analysis should be
done at maximum load.

Normal Spectrum

• All peaks are of low amplitudes

• No natural frequency of gear excited
 Tooth Cracked Spectrum

•GMF may not change

•High amplitudes of side bands
•Presence of natural frequency of gear (fn)
 Gear misalignment

•Excites harmonics of GMF with side bands

•Amplitudes 2GMF or 3GMF higher than 1GMF
 Resonance

Resonance occurs when forcing frequency coincides with the natural frequency
 Motors

• All electrical machines vibrates at 2 . line frequency.

• The reasons are expanding and collapsing magnetic fields.
• This vibration is normal .

Faults possible to detect with vibration analysis:

• Rotor thermal bow
• Air gap eccentricity
• Loose rotor
• Eccentric rotor
• Loose windings

Data required for analysis :-

• No. of stator slots (SPF)

• No. of rotor bars (RBPF)
• Line frequency (LF)
• Slip frequency (SF)
 Instrument types

Overall level meters. FFT data collectors.

Real time spectrum analyzers.