HISTORY OF MAINTENANCE

• START OF INDUSTRIAL REVOLUTION- Breakdown

Maintenance

• POST WW II TO 1980s- Preventive Maintenance

• POST 1980s - Predictive Maintenance

VIBRATION MONITORING (VM)

WHAT IS VIBRATION
Vibration is response of a system to an internal and
External stimulus(either impact or periodic force)causing
it to oscillate or pulsate.
Displacement Time
1.FREQUENCY – How many times the
machine vibrates per minute or per second
Often expressed in multiples of rotative speed
of the machine
2. AMPLITUDE – How much vibration,
 WHAT IS PHASE
PHASE - How the member is vibrating in relation with reference
point. It allow to determine whether events are in phase or out of
phase.
Phase angle is defined as the no. of degrees from the Keyphasor
pulse to the first positive peak of vibration.
 It is used to balance the rotating machines and diagnose other
problems
 VIBRATION AMPLITUDE
1. DISPLACEMENT : Displacement is TOTAL TRAVEL OF MASS
BACK AND FORTH. Expressed in microns (0.001 mm) or mils
(0.001”)

2. VELOCITY - SPEED OF MASS.. Expressed in mm/s or in/s.

3. ACCELERATION - RATE OF CHANGE OF VIBRATION

VELOCITY. (acceleration due to earth's gravity) or mm/s2 or in/s2.
 FORM
Vibration form is the raw waveform displayed on an
oscilloscope.
 TIME BASE Presentation: It is amplitude versus
time representation of the waveform
 ORBIT Presentation: It displays the o/p of two
transducers at 90 degree angles to one another.

POSITION
 Radial shaft position is a measurement of the shaft
centerline position with in radial bearing.
 Misalignment, external preloads and bearing wear
can be detected by this.
Vibration Instrument & Transducers:

INSTRUMENT:

 DATA COLLECTOR - Collects overall vibration reading, may

have storage facility. Operates in constant frequency range.
 TRANSDUCERS - These are accelerometers, velocity
transducers and proximity transducers.
PROXIMITY TRANSDUCER:
The system basically consists of probe, extension cable
and proximitor.
Probe: The coil is air core coil in this case. Coil end of the
probe ends in coaxial cable.
Front View Side View

. Air type coil

In Jerp proximitor is 3300XL series

PROXIMITY TRANSDUCER:
Proximitor: 100 mils

Eddy Current

RF Signal
Freq 500 kHz-2 MHz

Extension Proximitor
cable & probe
Demodulator

L
Oscillator

If the target is not moving than the o/p signal is

negative DC voltage and if the target is moving fast, it is a varying
DC (AC) signal. Thus in case of vibration the o/p of proximitor
will have both AC & DC component.
Velocity Transducer system operation:

 In low frequency ranges there will be no relative motion and output

will be zero.

The extension cable connects the transducer to monitor or VDC

converter

The higher freq part of the frequency range is compensated by

cable capacitance.

The lower end of transducer operating frequency will depend

on spring stiffness
 Acceleration Transducer system operation:
Electronic component is a charge amplifier that amplifies
charge from piezoelectric crystal and gives mV o/p.

The extension cable connects the transducer to interface module

than to monitor.

Interface module amplifies the accelerometer o/p and provides

the bias for o/p Signal for ok detection and necessary electronics to
drive the capacitive load.

Accelerometers are used for very high freq signals. There

operating band is very large from 10 Hz to 30 kHz.
Velomitors:

It includes the accelerometer transducer and the integ

-rated circuit to give velocity output for bearing housing
application.

This way it does not require interface module to connect

to the Monitor.

Its Operating range is from 10 to 5000 Hz compared to

4.5 Hz to 1000 Hz for velocity transducer.
When To Use Displacement . Velocity . Or Acceleration

• DISPLACEMENT IS USEFUL FOR FREQUENCIES

LESS THAN 600 CPM
• VELOCITY IS USEFUL FOR FREQUENCIES
BETWEEN 600 TO 120000 CPM
• ACCELERATION IS USEFUL FOR FREQUENCIES
OVER 120000 CPM
Advantages Of Vibration Measurement

• DISPLACEMENT IS STRESS INDICATOR.

• VELOCITY IS SEVERITY INDICATOR.

• ACCELERATION IS FORCE INDICATOR.

POSITION MEASUREMENT:
Following are the different position measurements.

A. Axial position: It measures change in rotor position in axial

direction. Measurement is made with proximity probe with
reference point.
Thrust Position: Position of thrust collar in the thrust bearing
is measured.

• If the end of the shaft is accessible by end plate than sensor is

mounted externally. If sensor is mounted internally it is
installed directly through thrust bearing.
Thrust collar

A&B probe
Shaft
POSITION MEASUREMENT:

Rotor position: Only diff that it is made with respect to

machine case for large size machines. Two diff. transducers
are used . This way it takes care of any movement of thrust
bearing assembly.

B. Radial position: Shaft centerline position with in the

bearing ,and the dynamic motion of the shaft relative to it is
analysed Proximity probe in XY plane(45 deg) are used to
measure vibration.
Rubs, imbalance and bearing stability etc. are detected by it.
D. Case Expansion:
It is the measurement of turbine case movement relative
to fixed reference.
• Two LVDTs located at each corner of turbine shell are
used for measurement.
• The measurement enables to determine that case&rotor
grow thermally similarly.

E. Eccentricity:
Amount of bow in the rotor measured at slow speed.
• Eccentricity collar is designed on the rotor to measure
eccentricity by proximity probe.
Different vibration parameters and there measurement:

Parameters Transducer type Location

Shaft radial vibration XY proximity probes Each bearing
Bearing cap vibration XY velocity transducers Each bearing housing
Differential expansion 50mm Differential HP case
Expansion (proximity) IP case
Transducer LP cases1 and 2
Eccentricity Proximity probe HP shaft
IP shaft
Cylinder expansion DC LVDT HP case
IP case
Vibration phase reference Keyphasor probe Governor end
Shaft position Proximity probe Thurst bearing
TRANSDUCER MOUNTING CONSIDERATION:
 For radial vibration measurement the target area must have uniform
conductivity and permeability, free of surface irregularities and
residual magnetism.

Each transducer requires sufficient side clearance and shaft surface

target area to measure accurately

Thermal expansion of the rotor should not affect the operation of the
sensor, in addition to it the machine operation should not affect the
sensor. Like wise the installation of sensor should not affect the
machine operation.

Extension cables should be securely fastened inside the machine.

Single point grounding should be used for entire system.

Selection of Vibration Instrument & Transducers:

Anticipated vibration signal shall fall within various constraints

and the type of sensor chosen is suitable for intended
environment.

The o/p sensitivity of the instrument should be considered i.e.

how much voltage will be generated for given level of vibration.

Frequency response of the sensor i.e. sensitivity v/s frequency is

checked to determine the usable frequency range of sensor.
The high and low frequency cutoff are compared with signals
under measurement.

Maximum operational vibration that can be measured without

over loading the electronics is also considered.
Selection of Vibration Instrument & Transducers:

The sensor should have adequate sealing and it should not be

exposed to high temperature and high shocks.

Barrier strip(Zener devices) is required for the sensors to

be mounted in hazardous area.

For general purpose sensors, low end freq. Performance is

sacrificed in favor of better turn on and shock recovery response
Shock pulse Measurement:
When a object hits another surface, a pressure wave spreads
through the material of both bodies, this wave quickly dampens
out.
The pressure wave that first goes through the material( before it
starts Vibrating) is called the shock pulse.
Amplitude of the shock wave is relative to the velocity of impact
Second phase of impact(collision) is vibration that we filter out
Combined with special accelerometer, which is designed with
special characteristic for shock pulse measurement.
Piezoelectric crystal generates signals for high freq (36kHz)
small shock pulses, o/p is filtered by band pass filter
The shock pulse analysis reveals the mechanical looseness,
misalignment, imbalance, gears, bearing defects etc.
 Vibration Analysis

• Which frequencies exist and what are the relationships to the

fundamental exciting frequencies.
• What are the amplitudes of each peak
• How do the peaks relate to each other
• If there are significant peaks, what are their source
Unbalance:

Vibration is predominantly
in radial direction
Phase difference is fairly
constant
Bent Shaft:
Misalignment:

 Angular misalignment is caused by high axial vibrations ,

peaks will be observed for 1and 2 times the axial vibrating
frequency.180 deg phase change will be observed across the
coupling,Symptoms could indicate coupling problem.

 Parallel misalignment is caused by high radial vibrations.

Peaks will be observed for 1,2 and 4 times the radial vibration
frequency.
BEAT VIBRATION:
BELT PROBLEMS:

 Worn loose or mismatched belts: In the spectrum 2x RPM is

dominant.Amplitudes are normally unsteady, sometimes pulsating
with either driver or driven RPM.

 Misalignment or unbalance pulley: Pulley misalignment will

produce high axial vibration at 1X RPM.

Belt Resonance: High amplitudes will be observed if the belt

natural frequency coincides with driven or driver RPM.
Phase Analysis:
phase analysis is used as a CONFIRMATORY tool,
because a large number of problems generate vibrations at
1x and 2x.

MISALIGNMENT AND BENT SHAFT shows

approximate 180 phase difference between inboard and
outboard bearing.

ROTOR RUB will cause instantaneous changes in phase.

RESONANCE exhibits exactly 900 phase change when

forcing frequency coincides with natural frequency and
approaches 1800 phase change after passing through
natural frequency.

During phase survey sudden change in phase readings

indicates either looseness or crack.
Start up / Coast down Analysis:

MONITORING OF VIBRATION AND PHASE AGAINST

RPM DURING STARTUP AND COAST DOWN.
PLOT OF VIBRATION AGAINST RPM AND PHASE
AGAINST RPM IS CALLED “BODE PLOT”
WHAT IS THE INFORMATION IN THE PLOT?

1. VIBRATION AND PHASE AT OPERATING SPEED.

2. CRITICAL SPEED OF THE ROTOR.
3. RIGID / FLEXIBLE ZONE OF THE ROTOR.
4. STIFFNESS / DAMPING / MASS CONTROLLED
REGION.
VIBRATION SIMULATOR:
TK3 Instrument: It is a test kit used to check the response of
the vibration sensor, we can check the response of the sensor in its
operating range. Healthiness and response of the probe can be
checked respectively by micrometer and rotating disk.

:
1. Bentley Nevada :3500 systems.
2 Data Manager 2000 for analysis.
3 Data collectors
P&ID