Vibration Monitoring & Analysis

Vibration Monitoring

What is Vibration ?
It is motion of mechanical parts back and
forth from its position of rest /neutral
position.
Vibration Monitoring
What causes Vibration ?

Induced Force
&
Freedom for Movement
 Vibration Monitoring
Harmful Effects of Excess vibration
• Increased load on BRGs: Reduced BRG Life
• Higher Forces on Mountings:
Foundation Loosening and Damage of
Support Structure
• Increased Stresses of M/c : Risk of fatigue
components
 Vibration Monitoring
Harmful Effects of Excess vibration
• Decreased Equipment efficiency.
• Reduced Output Quality.
• Increased Maintenance Cost due to
more Component Failures and
Unplanned Operations
• Unsafe Operating Environment
 Vibration Monitoring
Problem Identifications
• Unbalance
• Misalignment
• Mechanical Looseness
• Antifriction / Sleeve Bearing Defects
• Gear Defects
 Vibration Monitoring
Problem Identifications
• Belt Defects
• Impeller / Blade Defects
• Bent Shaft
• Electrical Problems
• Resonance
 Vibration Monitoring
Fundamental Realities
• All Machines vibrate.
• An increase in vibration level is a sign of
trouble & amplitude of Vibration depends on
the extent of defect in the machinery
components
• Each trouble will create vibration with different
characteristics
VIBRATION FUNDAMENTALS

90
Upper Limit

Neutral Position 180

TIME

Lower Limit
Period(T) 270
(1 complete cycle)
Characteristics of Vibration
• Vibration characteristics are
Displacement
Amplitude
Velocity

Acceleration

Frequency Hz or CPM

Phase Angle or clock face

 Parameter Selection
• Frequency sensitivity
Displacement <600CPM
Velocity 600-60,000CPM
Acceleration >60,000CPM
Spike Ultrasonic range
Energy/SEE
Frequency sensitivity
Vibration Monitoring

Displacement

Velocity

Acceleration
 FFT
FAST FOURIER TRANSFORM.

• THE PROCESS OF TRANSFORMING TIME

DOMAIN SIGNAL TO FREQUENCY
DOMAIN.
• THE TIME DOMAIN SIGNAL MUST
FIRST BE SAMPLED AND
DIGITIZED.
FFT SPECTRUM ANALYSIS
A method of viewing the vibration signal in a way that is more useful for analysis
is to apply a Fast Fourier Transformation (FFT). In non-mathematical terms, this
means that the signal is broken down into specific amplitudes at various
component frequencies.

Indian Institute For Production Management

Time Domain - overall data is the sum of

all exciting and reacting forces

Rolling
Imbalance Element
Bearing
Gearmesh
Coupling
chatter
Resultant Complex
Waveform

Time
 Spectrum Analysis

Enables precise evaluation of

machinery condition and prediction
 Fmax, LINES, AVERAGES.

• Fmax REPRESENTS THE MAXIMUM

FREQUENCY RANGE IN CPM OR HZ TO BE
SCANNED BY THE INSTRUMENT.
• Fmax SHOULD NOT BE SET TOO HIGH SO
THAT THE RESOLUTION AND ACCURACY
SUFFERS OR IT SHOULD NOT BE TOO LOW
SO THAT WE MISS SOME IMPORTANT HIGH
FREQUENCIES.
 GUIDELINES FOR SETTING Fmax.

• FOR MACHINES HAVING ANTI-FRICTION

BEARINGS:- Fmax = 60 x RPM

• FOR MACHINES HAVING SLEEVE

BEARINGS:- Fmax = 20 x RPM

• FOR GEAR BOXES:- Fmax = 3.25 x GMF

 LINES OF RESOLUTION
• THE RESOLUTION IS THE NUMBER OF LINES
OR CELLS WHICH ARE USED TO CALCULATE
AND DISPLAY THE FREQUENCY SPECTRUM.
• THE BANDWIDTH CAN BE CALCULATED BY
DIVIDING Fmax BY THE LINES OF RESOLUTION.
• THE GREATER THE NUMBER OF LINES , THE
BETTER IS THE ACCURACY.
FREQUENCY F max
RESOLUTION Bandwidth =
total lines of resolution

total lines of resolution

lines or bins or cells

Amplitud

of resolution
e

Frequency Fmax
Spectrum Data Collection Time
• FFT Calculation Time = Time to calculate
FFT from Time Waveform [assuming no
overlap processing]

(60) ( #FFT Lines) (#Averages)

FFT Calculation Time =
Frequency Span

Where: #FFT = Number of FFT Lines or Bins in Spectrum

# Averages = Number of Averages
Frequency Span measured in CPM
FFT SPECTRUM
 OVERALL VIBRATION
Total summation of all the vibration,with no
regard to any particular frequency.
OVERALL VIBRATION
Overall vibration is the total vibration energy measured
within a frequency range. Measuring the “overall”
vibration of a machine or component, a rotor in relation
to a machine, or the structure of a machine, and
comparing the overall measurement to its normal value
(norm) indicates the current health of the machine. A
higher than normal overall vibration reading indicates
that “something” is causing the machine or component
to vibrate more.
 Overall Vibration
Total summation of all the vibration,with no
regard to any particular frequency.

OA = A1 2 + A2 2 + ………………………+An 2

NBF
OA=Overall level of Vibration Spectrum , Ai = Amplitude of each FFT line
n = No. of FFT Lines of resolution , NBF= Noise Bandwidth for Window chosen
NOTE: Don’t be concerned about the math,
the condition monitoring instrument
calculates the value. What’s important to
remember is when comparing overall
vibration signals, it is imperative that both
signals be measured on the same frequency
range and with the same scale factors.
 What is Phase?
• The position of a vibrating part at a given
instant with reference to a fixed point or
another vibrating part.
• The part of a vibration cycle through which
one part or object has moved relative to
another part.

The unit of phase is degree where one

complete cycle of vibration is 360 degrees.
Phase is a measurement, not a processing
method. Phase measures the angular
difference between a known mark on a rotating
shaft and the shaft’s vibration signal. This
relationship provides valuable information on
vibration amplitude levels,shaft orbit, and shaft
position and is very useful for balancing and
analysis purposes.
Vibration Phase
Additional
Illustration on
Phase
 PHASE AN ILLUSTRATION
30 Micron 32 Micron
10 degrees 10 degrees

Shaft centre line moves up and down in a planer fashion

PHASE AN ILLUSTRATION
30 Micron 32 Micron
10 degrees 190 degrees

Shaft center line moves up and down in a rocking fashion

MACHINE TRAIN MISALIGNMENT

TURBINE G/B HP COMP LP COMP

AXIAL PHASE 0 5 15 18 198 215

(degrees) 10 12 22 24 210 220
12 10 20 22 208 218
8 6 16 20 200 210

Note: All phase readings corrected for pickup direction

Comparing Overall Levels
Across Mounting Interfaces
 Phase application

C
A B

A 5 Microns, 10 degrees
B 7 Microns, 12 degrees
C 25 Microns, 175 degrees
Bolt at C is loose
Vibration Analysis of

Common Problems
 Vibration Analysis
Unbalance
• Amplitude proportional to the amount of
unbalance
• Vibration high normally in radial direction
(may be also in axial direction incase of
overhung and flexible rotors ).
• 1* RPM vibration is greater than 80%
(normally) of the overall reading.
 Vibration Analysis
Unbalance
• Horizontal and vertical 1* RPM amplitude
should be nearly same, although it also
depends on system rigidity on the
particular direction.
• Other frequency peaks may be less than
5% of the 1*RPM amplitude
• Phase shift of 90 deg. When sensor
moves from horizontal to vertical.
 UNBALANCE
• Operating conditions such as load, flow
condition and temperature effect
unbalance
– Balance under normal operating conditions
• Changes in track and pitch angle of fan
blades can result in “Aerodynamic
Unbalance”
Typical Spectrum For
Unbalance
 MISALIGNMENT

• BIGGEST PROBLEM INITIALLY

• Operating temperature can affect
alignment
– Machines aligned cold can go out when
warm
• Bases or foundations can settle
• Grouting can shrink or deteriorate
• Increases energy demands
 MISALIGNMENT

• Forces shared by driver and driven (not

localized)
• Level of misalignment severity is
determined by the machines ability to
withstand the misalignment
– If coupling is stronger than bearing the
bearing can fail with little damage to the
coupling
 Three Types of Misalignment

• Combination (most common)

• Angular
• Parallel or Offset
 General Characteristics Of
Misalignment
• Radial vibration is highly directional
• 1X, 2x, and 3x running speed
depending on type and extent of
misalignment
– Angular 1x rpm axial
– Parallel 2x rpm radial (H & V)
– Combination 1,2,3x rpm radial and
axial
Typical Spectrum for
Misalignment
 Vibration Analysis
Misalignment
Angular Misalignment
• High axial vibration
( Greater than 50% of the radial vibration)

• 1* , 2*, 3* RPM normally high.

• 180 deg. Out of phase across the coupling

 Angular Misalignment
• Produces predominant 1x rpm component
• Marked by 180 degree phase shift across the
coupling in the axial direction
 Vibration Analysis
Misalignment
Off-Set Misalignment
• High Axial vibration. Also shows high radial
vibrations.
• 1*, 2*, 3* RPM high. 2* often larger than 1*
• In case of severe misalignment, much high
harmonics (4* - 8*) or even a whole series of
high frequency harmonics will be generated.
• 180 deg. Out of phase across coupling
Parallel Or Offset Misalignment
• Produces a predominant 2x rpm peak in the
spectrum
• Marked by 180 degree phase shift across the
coupling in the radial direction.
Typical Spectrum for
Misalignment
Axial Phase Showing
Misalignment
Other Types Of Misalignment
 Vibration Analysis
Mechanical Looseness
Caused by structured looseness / weakness of
machine feet, base plate or foundation; also by
deteriorated grouting, loose base bolts and
distortion of the frame or base.
• Radial vibration high
• 2* RPM & 1* RPM dominant
• 180 deg. Phase differences between mating
surfaces which have looseness between
them.
 Vibration Analysis
Mechanical Looseness
Caused by structured looseness / weakness of
machine feet, base plate or foundation; also by
deteriorated grouting, loose base bolts and
distortion of the frame or base.
• Radial vibration high
• 2* RPM & 1* RPM dominant
• 180 deg. Phase differences between mating
surfaces which have looseness between
them.
 Looseness

• Looseness produces
2X RPM Freq.
 Vibration Analysis
Mechanical Looseness
Caused by looseness in bearing housing bolts and
cracks in the frame structure.

• Radial vibration high

• 2* RPM normally dominant. 0.5*, 1* and 3* RPM
may also be present
• Substantial Phase difference between mating
surfaces which have looseness between them
 LOOSENESS
• Not an exciting force
• Allows exciting frequencies already
present to exhibit much higher
amplitudes
• Loss or reduction in normal stiffness
• Caused by:
– loose mounting bolts
– deterioration of grouting
– cracked welds
 Two Types Of Looseness

• Looseness of Rotating Components

– Loose Rotors
– Bearings Loose on the Shaft or in Housing
– Excessive Sleeve Bearing Clearances
• Looseness of Support System
– Loose Mounting Bolts
– Grouting Deterioration
– Cracks
– Poor Support
– Frame Distortion
 Looseness Of Rotating
System
• Rattling condition cause impacts due to
excessive clearance in a rolling element
or sleeve bearing
• Impacts cause multiple running speed
harmonics to appear in the spectra
• Identified by:
– multiple harmonics
– unstable phase
– highly directional radial vibration
Typical Spectrum for Looseness
of Rotating System
Looseness Of Support System

• FFT readings show 1x rpm, 2x rpm, and 3x

rpm components
• Structural looseness / weakness will cause
high 1xrpm peak in FFT
• Identified by
– Highly directional radial vibration
– Bouncing
– Taking comparative phase readings across
interfaces and look for amplitude variation
– Typically loose in vertical direction
Looseness Of Support System
 Modern Trend
in
Vibration Technology
 Condition Monitoring
System Integration
CENTRALISED DISTRIBUTED
WALKAROUND SURVEILLANCE ON-LINE
PROTECTION PROTECTION
ANALYSIS

PROTECTION

PERIODIC CONTINUOUS

OFF- LINE ON - LINE

NETWORK DCS
SOFTWARE
PdM TECHNOLOGIES CMMS
Overall Data Acquistion
4-20mA

MONITOR
THE DCS

DCS OUTPUT
time waveform
Overall Data Trends-
this is what the DCS records

hi alarm

lo alarm

current value changes over time

The limitation is that it does not adequately reflect changes
at higher frequencies which can increase by 100% but only add
1% to the overall energy level
 Vibration Analysis
Protection Monitor
and / or

Data Collector
Vibration Spectrum

transducer

time waveform
Band Alarms, associate with each rotating element

hi alarm
lo alarm

frequency bands
Band Trending, the new way forward

hi alarm

lo alarm

changes over time

Trend and alarm the:

•Machine unbalance
•Alignment
•Gear mesh
•Bearings etc
Emonitor Odyssey: spectrum band alarming though its
diagnostic tools feature for both On & Off line gives advanced
machinery analysis and reduces False Alarms
EMONITOR Odyssey: Frequency Band
Trends

Frequency Trend of Single Measurement

 DIAGNOSTICS - the advantage of frequency band trending
• Root cause analysis is a complex machine specific
exercise considering all eventualities
• Expert systems are a one off diagnosis and do not
show a trend
• Frequency band trending is specific to root cause
analysis
• Band alarming also indicates vibration signals that
are outside the established norms
• Trending alignment, unbalance, gear meshing and
bearing condition condition is more specific
• A complex issue simplified without the need of
specialist customisation and regular updates
 DCS Limitations - Summary
• We have shown that putting total belief in the DCS vibration
trend is highly risky
• Machinery failures still happen with on-line vibration
monitoring with 4-20mA data to the DCS. Most causes are
due to higher frequency signals swamped by the overall
levels.
• Advanced machinery protection through Frequency Band
Trending and Alarming - more specific than an Expert system.
• The latest S/w based Analysers incorporates Narrow Band
Alarming. They offer machinery protection and narrow band
alarming.
• A lower cost solution is periodic manual Data Collection.
ESHAPE: Modal analysis using phase for
advanced diagnosis and better understanding of
system response
 On line Vibration and other
monitors
• Innovative, fully-digital design
• Exceeds API 670 specification
• Widely-used system
• Fully field programmable
• Low installation cost
• ModBus protocol
 TYPICAL APPLICATION
HP IP LP ALT.

DRIVERS DRIVERS DRIVERS DR IVERS DR IVER S DR IVERS DRIVERS

IRD IRD IRD IRD IRD IRD IRD

VI BRATI ON VI BRATION VIBRATI ON VIBRATI ON VI BRATI ON VI BRATI ON VI BRATI ON

MONITOR MONITOR MONI TOR MONI TOR MONI TOR MONI TOR MONITOR

CH. 1 CH. 2 CH. 1 CH.2 CH. 1 CH. 2 CH. 1 CH. 2 CH. 1 CH. 2 CH. 1 CH. 2 CH. 1 CH. 2

TACHO TACHO TACHO TACHO TACHO TACHO TACHO

IRD IRD IRD IRD IRD IRD IRD

VI BRATI ON VI BRATION VIBRATI ON VIBRATI ON VI BRATI ON VI BRATI ON VI BRATI ON

MONITOR MONITOR MONI TOR MONI TOR MONI TOR MONI TOR MONITOR

CH. 1 CH. 2 CH. 1 CH.2 CH. 1 CH. 2 CH. 1 CH. 2 CH. 1 CH. 2 CH. 1 CH. 2 CH. 1 CH. 2

TACHO TACHO TACHO TACHO TACHO TACHO TACHO

 POWER PLANT INTEGRATION
DCS OPERATIONS ENGINEERING ODYSSEY
SERVER

DATA VIBRATION
LOGGER ANALYSER

BFP ID
FS HP LP GEN EX
BFP FD

CWP PA
TURBINE STATOR END GATEWAY
SUPERVISORY WINDING AUXILIARIES
TO CMMS
 Plant Integration with LAN or WAN
DCS ENGINEERING ODYSSEY
CLIENT SERVER

VIBRATION
ETHERNET ANALYSER

CONTROL ROOM No 1 CONTROL ROOM No 2 CONTROL ROOM No 3

FS HP LP GEN EX FS HP LP GEN EX FS HP LP GEN EX

GATEWAY
TG 1 TG 2 TG 3 TO CMMS
ANURAKSHAN
 NETWORKING THE INFORATION - LAN
/ WAN e.g.
RIHAND

TALCHER
PLANT
OPERATIO

NS
VINDHYACHAL

NOIDA HQ

GATEWAY CM CELL
TO CMMS
ANURAKSHAN

KAYAMKULAM
UNCHAHAR
 Using PlantLink
Digital Picture of Plant

Vibration Trend Plot

Hyperlink to
equipment
Hierarchy

Automatic E-Mail notification on

Equipment Alarm Status

Click on Measurement
Label to link to plots or
other views.
Information however you want it !
X-Window Screen Captures
Scenario of Instruments &Sensors & Probes
• Velocity sensors are made in India
• Accelerometers range over 150 types
– standard
– Low frequency
– High temperature (Gas Turbines)
– Special application
• Eddy current probes - comprehensive range
• Others available for process measurement
 Vibration Datacollectors

Many vendors

Select on ‘Fitness
for Purpose’
Intrinsic Safety
Dust & Moisture proof
Diagnostic Capability