999/7 Soi Anamai, Suanluang, Suanluang, Bangkok 10250 Tel. 02-7214191-2 Fax. 02-7214190 Contact: MR - Kosin Jitjaturunt Mobile: 66-81-5837797

999/7 Soi Anamai, Suanluang, Suanluang, Bangkok 10250
Tel. 02-7214191-2 Fax. 02-7214190

Contact : Mr.Kosin Jitjaturunt
Mobile : 66-81-5837797
Web site : www.advancesiam.com
Email : kosinj@advancesiam.com
INTRODUCTION
INTRODUCTION to
to
VIBRATION
VIBRATION TECHNOLOGY
TECHNOLOGY
2
What is Vibration?
Vibration is the motion of a body about a reference point caused by
an undesirable mechanical force.
Shaft vibration caused by the shaft
moving about the centerline of a
journal bearing.
-
(Vibration)

Vibration Excitation Sources

Mechanical
Looseness
Slot Frequency /
EM related
Unbalance
Bent Shaft
Gears
Blade Pass /
Fluid Related
Alignment
Motor
Mechanical
Resonances
Sam Shearm an
National Instruments
Journal (Fluid Film)

Bearings
Couplings
Rolling Element
Bearings
5
Vibration vs. Machine Life

3
L Life (Hours) = 16,666 x Rate

10
RPM
Load
RPM =
Rate = Load
Load = Load
210000
200000
190000
180000
10
170000
160000
150000
140000
130000
120000
110000
Machine Life
100000
90000
80000
70000
60000
50000
40000
30000
20000
10000
%
100
9 0%
8 0%
7 0%
6 0%
5 0%
4 0%
3 0%
2 0%
L = 25,000 Hrs.
1 0%
0%
200000
180000
160000
140000
120000
100000
80000
60000
40000
20000
0
Rotor Weight
[ ][ ],
3
Rate x 16,666
L = Load
RPM
10
For Example;
L10= Bearing Life Time in Running hours.
Centrifugal Fan Rotor

Blade Diameter = 1100 mm.
Rotor Load = 500 Kgs.
Speed = 1485 RPM
Rated Bearing Capacity = 10000 Kgs..
[ ][ ]
3
10000
L = 500 x 16,666
1485
10
From the above Equation,

the expected life time is about 89,787 Hours
7
Dynamic Load Vibration

Example ; Unbalance 30 g
30 g at 550 mm. = 16,500 g-mm.=1,650 g-cm.
2
W = mrw = mr x (2pf) ,
g
9.81
f = Frequency in Hz., (next page for detail)
= mr 2 x 3.14 x rpm
9.81
60
2
= 0.01 mr ( rpm / 1000 )
W = 0.01 x 1,650 ( 1485 / 1000 )

= 36.38 kg
From the previous Equation
[ ][ ]
3
10000 ] x 16,666 ]
L = [ 500+36.38 [ 1485
3
Rate
L = Load x 16,666
RPM
10
10
the expected life time is about 72,686 Hours

= 20 % lost in Life Time
A A = 2pr
v
=
w
r
,
a
=
w
v
+
2;
F = mrw w = 2p= 2pf
t
F = ma , F = Newton, m = kg Mass , a = m/s 2
Force 1 N can make mass 1 kg. have acceleration 1 m/s2
W = mrw ;
= 2p= 2pf
g
t
W = mg , W = Kg Force , m = kg Mass , g = 9.81 m/s2
Mass 1 Kg Force can make mass 1 kg. have acceleration 1 g.
w
10
MAINTENANCE
PREVENTIVE
BREAKDOWN
TIME BASE CONDITION BASE
-
-
-
-
-

- pump vane
balance journal babbit gearmesh
-
- 30%
11
BREAKDOWN Case Study

....
...
... ?
12
PREVENTIVE
PREDICTIVE
TIME BASE
SUBJECTIVE OBJECTIVE
-
-
-, Lube Oil
- , LOAD
-
* Overhaul

*
Overhaul Breakdown CORRECTIVE
- 15%
13
Time Base Case Study ( )
100,000

...
, , , , ,
, , , , , ,
, , , , ,
, , ,
, ,
...
14
3 Days Later...
15
Time Base Case Study ( )

!
,
......
,
!
...
...
16
PREDICTIVE
SUBJECTIVE
-
-
-
OBJECTIVE
-

SUBJECTIVE
-
-
- OBJECTIVE

17
Subjective Maintenance Case Study

..
...
...
...

...
!
18
Example
Reduction cost for each Maintenance Philosophies
Electric Power Research Institute study on annual costs of
the three philosophies
Breakdown = $17-18 / HP
Preventive = $11-13 / HP
Predictive = $7-9 / HP
19
OBJECTIVE
-Machinery Vibration
-Lube Oil Analysis / Wear Particle Analysis
-Ultrasonic testing
-Motor Current Analysis
-Infrared Thermography
-Bearing Temperature
-Sound Meter and etc.
20
CbM Program Advantages:

Minimizes machine damage and allows scheduling of downtime,
labor, materials
Helps eliminate costly trial and error approaches to solving
problems
Allows machines in good operating condition to continue to run

Eliminates unnecessary overhauls
Improves safety and quality performance
Facilitates Root Cause Analysis
Assists in redesigns or modifications
Increased overall knowledge for decision makers
Properly schedules Preventive Maintenance (PM) activities
21
Vibration CbM Program

Condition Monitoring consists of four steps:
Detection
Analysis
Correction
Feedback/Root Cause
22
Vibration
( Criteria Acceptance )
23
24
ISO 2372 Criteria

Limit, mm/s, rms
Class I
Class II
Class III
Class IV
Class V
71
45.0 - 71.0
28.0 - 45.0
18.0 - 28.0
11.2 - 18.0
7.1 - 11.2
4.5 - 7.1
2.8 - 4.5
1.8 - 2.8
1.12 - 1.8
0.71 - 1.12
0.3 - 0.71
0 - 0.3
D
D
D
D
D
D
D
C
C
B
B
A
A
D
D
D
D
D
D
C
C
B
B
A
A
A
D
D
D
D
D
C
C
B
B
A
A
A
A
D
D
D
D
C
C
B
B
A
A
A
A
A
D
D
D
C
C
B
B
A
A
A
A
A
A
Remark : 1) Amplitude in mm/s

2) Detection type in rms.
3) Band Pass Filter as 10-1000 Hz.
25
ISO 10816 Part 3

Industrial Machines with nominal power above 15 kW and nominal speeds between 120 rpm and 15,000 rpm when measured insitu
Velocity
10 -1000 Hz, r > 600 rpm
2 - 1000 Hz, r < 600 rpm
Pumps > 15 kW
Radial , Axial, Mixed Flow
Group 4
Group 3
Integrated Driver External Driver
Limit, mm/s, rms
Rigid
Flexible
Rigid
> 18.0
11.0 - 18.0
7.1 - 11.0
4.5 - 7.1
3.5 - 4.5
2.8 - 3.5
2.3 - 2.8
1.4 - 2.3
0.7 - 1.4
0.0 - 0.7
D
D
D
D
C
C
B
B
A
A
D
D
D
C
B
B
B
A
A
A
D
D
D
C
B
B
B
A
A
A
Medium Size Machines

15 kW < Power < 300 kW
Group 2
160 mm < Motor Height < 315 mm

Flexible
Rigid
Flexible
D
D
C
B
B
A
A
A
A
A
D
D
D
D
C
C
B
B
A
A
D
D
D
C
B
B
B
A
A
A
Large Machines
300 kW < Power < 50 MW
Group 1
315 mm < Motor Height
Rigid
Flexible
D
D
D
C
B
B
B
A
A
A
D
D
C
B
B
A
A
A
A
A
Newly Commissioned
Unrestriced long-term operation
Restriced long-term operation
Vibration causes damage
26
ISO 10816 Part 3

Industrial Machines with nominal power above 15 kW and nominal speeds between 120 rpm and 15,000 rpm when measured insitu
Displacement
10 -1000 Hz, r > 600 rpm
2 - 1000 Hz, r > 120 rpm
Pumps > 15 kW
Radial , Axial, Mixed Flow
Group 4
Group 3
Integrated Driver External Driver
Limit, micron, rms
Rigid
Flexible
Rigid
> 140
113 - 140
90 - 113
71 - 90
56 -71
45 -56
36 -45
28 -36
22 -28
18 -22
11 -18
0 - 11
D
D
D
D
D
D
D
C
C
B
B
A
D
D
D
D
D
C
C
B
B
B
A
A
D
D
D
D
D
C
C
B
B
B
A
A
Medium Size Machines

15 kW < Power < 300 kW
Group 2
160 mm < Motor Height < 315 mm

Flexible
Rigid
Flexible
D
D
D
C
C
B
B
B
A
A
A
A
D
D
D
D
C
B
B
B
B
A
A
A
D
D
C
C
B
B
B
A
A
A
A
A
Large Machines
300 kW < Power < 50 MW
Group 1
315 mm < Motor Height
Rigid
Flexible
D
D
D
C
C
B
B
B
A
A
A
A
D
C
C
B
B
B
A
A
A
A
A
A
Newly Commissioned
Unrestriced long-term operation
Restriced long-term operation
Vibration causes damage
27
Vibration
28
Vertical
/
p
r
m
e
Pu low
B
o
M
r
o
t
Axial
Horizontal
29
Vertical Pump Case

Axial
Vertical
Motor
Horizontal
Pump
Discharge
30
Better
1)
Worse
Better
Worse
2)
3) (Load)
4) Bearing Housing
5) Vibration
Better
cover
Worse
2.03
7.57
31
Measurement Point Locations

MOH
MOV
MIH
MIV
PIH
PIV
POH
POV
POA
MOA
2 per bearing + 1 axial measurement per shaft

OB=TDS=NDE
IB=DS=DE
32
33
Vibration

- H, V, A
- V
V
34
Vibration
35
Vibration Amplitude
1) Displacement
2) Velocity
3) Acceleration
3.1) General G
3.2) G Spike Energy ( Demodulation for Bearing Detection )
4) dB , dB = 20 Log R
R ref
R =
R ref = Noise Vibration
36
Amplitude Units What You See
mm/s (millimeters/sec)
The
Thefrequencies
frequenciesremain
remainthe
thesame,
same,
but
butthe
theamplitudes
amplitudeschange
change
Acceleration
gs
m/s2(meters/sec2)
integrate
Velocity
ips (inches/sec)
integrate
The
Theunits
unitsare
areallallmathematically
mathematically
related
relatedsuch
suchthat
that
differentiate
m (0.001 millimeter)
differentiate
Displacement
mils (0.001 inch)
37
UNIT CONVERSION
A = 64 fV x 10
-5
-8
A = 202 f D x 10
V = 1562 A
f
V = 315 f D x 10
D = 495050 A
2
f
D = 317 V
f
-5
G, Pk
mm/s, Pk
Micron, Pk-Pk
38
What's the difference?

Acceleration,Velocity, & Displacement
The frequency range of interest
Acceleration
(high freq.)
Velocity
(general purpose)
Displacement
(low freq)
600 cpm
60,000 cpm
39
Type of measurement
Amplitude
rms
peak
peak-peak
Time
1 revolution
For Pure Sine Wave Form

peak-peak = 2 peak
= 2 x 1.414 rms
Avg = 0.637 Peak
40
Phase Measurement
Vibration pickup
Reflective tape
High spot
180
Tacho sensor
*The Tacho signal get

when the vibration is Peak*
Phase Measured between

the reflective tape and
heavy spot
Tach Pulse
180
360
Vibration
Signal
Time
41
Phase Angle
Phase Angle
: Phase Angle
42
Reflective tape
High Spot
Vibration pickup
90
180
90
180
270
360
Time
Tacho sensor
Vibration pickup
270
Tacho sensor
360
Time
Vibration Signal
Vibration pickup
90 180
270
360
Time
Phase Measured between the

reflective tape and heavy spot
Tacho sensor
Vibration pickup
90 180
270 360
Time
90 180
270 360
Time
Tacho sensor
Vibration pickup
5
Tacho sensor
43
Vibration pickup
High Spot
90
180
270
360
Time
90
180
270
360
Time
90
180
270
360
Time
90
180
270
360
Time
90
180
270
360
Time
Tacho sensor
Reflective tape
Vibration pickup
2
Tacho sensor
Vibration pickup
3
Tacho sensor
Vibration pickup
Phase Measured between the

reflective tape and heavy spot
Tacho sensor
Vibration pickup
5
Tacho sensor
44
Phase Comparison
In Phase:
180o Out of Phase:
45
Phase Comparison
In Phase:
180o Out of Phase:
46
Phase Comparison
+
Time
Time
Amplitude - A
Time
Amplitude - B
Amplitude - B
Amplitude - A
In Phase:
180o Out of Phase:
47
Vibration
48
All sensors are designed to measure one of the three
Sensors & Units
Velocity
Acceleration
mils (0.001 inch)

m (0.001 millimeter)
ips (inches/sec)
integrate
Displacement
Eddy Current
Probes
Velometers & Integrating

Accelerometers
mm/s (millimeters/sec)
gs
Accelerometers
m/s2(meters/sec2)
49
, NCPU (Non Contact Pickup Unit)

Eddy Current Probe
Displacement = The Distance the machine moved , Normal Output is 200 mV/ mil, Pk-Pk
50
Eddy Current Probe
51
Theory of Operation - NCPU

System Static Output
(-)
V
O
L
T
S
Linear Range
24
20
16
12
Gap Voltage
8
Gap
4
10
20
30
40
50
60
70
80
90
100
110
120
MILS
52
Theory of Operation - NCPU

System Dynamic Output
(-)
V
O
L
T
S
24
20
Vibration Amplitude
16
Average Gap Voltage
12
8
4
10
20
30
40
50
60
70
80
90
100
110
120
TIME (ms)
53
A NCPU System
54
|
|
|
|
|
DCS
EXAMPLE OF
NON-CONTACT PROBE
TO
A MONITORING
SYSTEM
3.61
H
L
P
L
I
T
mils pk-pk
D
A
A
D
I
S
R
S
T
6652
VIBRATI
ON
T
S
T
MONITO
R
MODBUS RS485
CH 1
TACHO
CH 2
S
E
L
Monitor Turbine, Compressor,

Gearbox, Pump, Journal/Plane Bearings ,
Unbalance, Misalignment, Centerline, Rubbing, Looseness Rotor
Probe Driver
56
UNIT IN RELATIVE VIBRATION

Display in Microns, 1/1000 mm.
Or in Mils , 1/1000 inch.
Analyze in ORBIT or Phase analysis as Nyquist/Polar
Or Bode Plot.
Example of Certification of Calibration
EDDY PROBE CALIBRATION REPORT

Machine: P201B
Date of Test: 16/09/02
Calibrated Probe P/N: 1909/30/05/1/05
Probe position: G-DEX
Calibration Equipment : TK3

Probe Resistance(Ohm) :
4.2 Ohm
Probe with Extension Cable : 12.2 Ohm
Calibrated with standard Extension Cable S/N: 8.5C
Standard Driver S/N: STDDRV_22-9.0D
System Cable Length: 9 m.
Target Material: 4140 Steel
Supply with load: -16.70 Vdc
Output per one mils of Gap = 1.633
Supply without load: -19.76 Vdc

GAP (inches)
VOLTAGE
STANDARD DEVIATION
SLOPE
0.00
0.720
2.00
1.28
N/A
0.01
0.718
2.00
1.282
N/A
0.02
2.017
3.63
1.616
129.9
0.03
3.570
5.27
1.696
155.3
0.04
5.321
6.90
1.578
175.1
0.05
7.168
8.53
1.364
184.7
0.06
8.984
10.17
1.181
181.6
0.07
10.627
11.80
1.171
164.3
0.08
12.301
13.43
1.130
167.4
0.09
13.916
15.06
1.148
161.5
0.10
15.183
16.70
1.514
126.7
Volts
Seismic Velocity
Velocity = The Displacement Per Time, Normal Output is 100 mV/inch/sec, Pk
Center
60
Center
61
( Accelerometer )
Acceleration = The Rate of Change of Velocity, Normal Output is 100 mV/G, Pk
62

( Top Exit ),
( Side Exit ),
Connector
63
Power supply Accelerometer Bias Voltage

( Voltage drop )

18-30 Volts DC
AC Vibration Signal in 100 mV/ G
12 Volts DC
0 Volt DC
64
Biased Output
65
Amplitude Accelerometer
66
Vibration
3
1
Typical Recommended maximum

frequency ranges for common
accelerometer mounting methods
67
Transducer Mounting Methods
Hand
Probe
Dual Rail
Magnet
Flat
Magnet
Mounting
Pad
Adhesive
Mount
Stud
Mount
Sensitivity Deviation
(dB) ~ Ref. 100 Hz
+40
+30
+20
+10
0
-10
-20
1.0
10
100
1000
10 000
100 000
Log Frequency (Hz)
68
Mounted Frequency Response
69
Vibration
Vibration Analysis
Analysis
Spectrum
Spectrum Analysis
Analysis Part
Part
70
Sound & Vibration

Sound waves cause vibration when
they impact a surface, such as your
ear drum
sound
vibration
Sound (pressure waves in the air) are caused

by the movement (vibration) of a solid
surface, such as the surface of a drum.
71
So, about that bike

Remember that bike you had
when you were 9 or 10?
It probably wasnt as
cool as this one!
72
So You Made it Cool

by attaching cards, cardboard, or
whatever else to the fork or spokes.
73
Remember the sound that it made

what you heard was something
like
A popping sound
Time
74
How often did it make the sound?

If the cards were attached to a spoke then.
You heard the pop once each time the
cards hit the fork, or ONCE PER
REVOLUTION of the wheel.
75

and if you pedaled fast enough that the wheel spun 60
times per second (tough kid!), then.
You would hear the pop 60 times per
second.
60 of these
every 1 Second
0
AArate
rateof
ofEvents
EventsPer
PerSecond
Secondisis
called
calledHz
Hz(like
(likethe
thecar
carrental
rental
folks)
folks)
76
And if you kept at that rate for a minute

If you pedaled fast enough that the wheel spun 60
times per second for 1 minute then.
You would hear the pop 3600 times per
minute.
60/sec x 60 seconds = 3600/minute
every
0
1 Minute
AArate
rateof
ofEvents
EventsPer
PerMinute
Minuteisis
called
calledcpm
cpm(Cycles
(CyclesPer
PerMinute)
Minute)
77
really tough kid!

Thats about 100 Miles Per Hour
78
If you drew what you heard

time
AAplot
plotof
ofthe
thesound
soundover
overtime
timeisis
called
calledaaTime
TimeWaveform
Waveform
InInthis
thiscase
caseits
itsmore
moreofofaapulse
pulsethen
then
aawave
but
well
get
to
that
wave but well get to that
79
What else did you hear?

what did you hear when you blew
past your kid brother?
Your bike
His bike
80
If you drew what you heard

0
20 Hz Time Waveform
Time
Timewaveforms
waveformsthat
thatinclude
include
only
onlyaasmall
smallsubset
subsetof
ofall
allof
ofthe
the
noise
noiseout
outthere
thereare
arecalled
called
filtered
filteredTime
TimeWaveforms
Waveforms
AAtime
timewaveform
waveformthat
thatincludes
includesall
all
of
ofthe
thesounds
soundsisiscalled
calledan
an
unfiltered
unfilteredTime
TimeWaveform
Waveform
60 Hz Time Waveform
Raw Time Waveform
81
Another way to look at it

What if I wanted to see, at a
glance, what the frequency of
every signal in a time
waveform was?
How would this be
represented on this ?
Hz
could also be cpm
82
The Spectra
Each signal (filtered
time waveform) would
be a line at whatever
frequency that it had
occurred at
little brothers bike
your bike
The
Thealgorithm
algorithmthat
thatdoes
doesthis
thisisiscalled
calledthe
the
Fast
FastFourier
FourierTransform,
Transform,ororsimply
simply
FFT.
FFT. Often
Oftenaaspectra
spectraplot
plotisiscalled
calledanan
FFT
FFTplot.
plot.
20 Hz
60 Hz
Hz
AAplot
plotthat
thatdepicts
depictsall
allof
ofthe
the
sounds,
sounds,each
eachrepresented
representedby
by
aaline
lineat
atthe
thefrequency
frequencyof
ofthe
the
sound
soundisiscalled
calledaaSpectra
Spectra-which
isisthe
plot
of
aa
which
the
plot
of
100
Spectrum.
Spectrum.
83

What if you had attached the cards to
the fork rather than to a spoke?
Then you would have heard the pop once
each time the cards hit a spoke! If there
were 10 spokes then you would have heard
a pop at a rate of 10 TIMES PER
REVOLUTION of the wheel.
ten pulses per one revolution 84
Orders
cards on fork (600 Hz)
cards on spoke (60 Hz)
A frequency equal to the speed of shaft (wheel) is commonly called the

1x running speed vibration, or simply
1x
Hz
10x (if there are 10 spokes)

AAdiscrete
discretefrequency
frequencythat
that
is
isequal
equalto
toaamultiple
multipleof
of
the
thespeed
speedof
ofthe
theshaft
shaftis
is
800
called
calledthe
theNx.
Nx.
85
Time Waveform
+
Amplitude
Heavy Spot
Time
3000 RPM
Rotation
1 revolution
3000 RPM
3000 cycles per minute
50 Hz
50 cycles per second
1 Order
One times turning speed
86
Time Waveform
Amplitude
Time
3000 RPM
1 revolution
4 blades
4 X 3000 RPM
=
=
=
=
Vibration occurs 4 times per revolution

Vibration occurs at 12,000 cycles per minute
12,000 CPM
200 Hz
87
Time Waveform
Amplitude
12 tooth
gear
Time
1 revolution
3000 RPM
12 teeth are meshing every revolution of the gear

12 x 3000 RPM
= vibration occurs at 36,000 cycles per minute
= 36,000 cpm
= 600 Hz
88
Time Waveform
+
0
-
Time
+
0
Time
+
0
Time
89
Time Waveform
+
Time
Time Waveform contains all the different

frequencies mixed together.
90
Time Waveform
Example of a time waveform
91
Signal Acquisition
Transducer
Amplitude
Overall
Energy
Waveform
Time
FFT
DATA
COLLECTOR
Amplitude
PROTECTION
SYSTEM
Spectrum
Frequency
92
Amplitude
FFT Signal Processing
Tim
e
Amplitude
Amplitude
Tim
e
y
nc
e
qu
re
93
Frequency Domain
FFT - Fast Fourier Transform
Separates individual frequencies
Detects how much vibration at each frequency
94
Frequency Domain
+
0
Time
Frequency
1x
+
0
Time
Frequency
4x
+
0
-
Time
12x
Frequency
95
A Typical FFT Spectrum

Many distinct peaks
96
A Typical FFT Spectrum
Specific peaks typically correlate to

Specific machine faults
Related to machine speed
97
Vibration
1) Frequency
2) Amplitude
3) Phase
4) Demodulation ( Spike Energy )
98
Frequency
CPM = Cycles Per Minute
= Hertz x 60 Seconds/Minute
= Cycles x 60 Seconds
Seconds
Minute
Hertz = Cycles Per Second
= CPS
= CPM
60 Seconds / Minute
= Cycles / Minute
60 Seconds / Minute
99
Vibration Amplitude
1) Displacement
2) Velocity
3) Acceleration
3.1) General G
3.2) G Spike Energy ( Demodulation for Bearing Detection )
4) dB , dB = 20 Log R
R ref
R =
R ref = Noise Vibration
100
Type of measurement
Amplitude
rms
peak
peak-peak
Time
1 revolution
For Pure Sine Wave Form

peak-peak = 2 peak
= 2 x 1.414 rms
Avg = 0.637 Peak
101
mm/s
micron
All are the same Spectrum, just

change
the unit by calculation
102
Whats an Fmax and Why Does It Matter?

Fmax is the maximum frequency of the spectrum.
If you don't collect it, you can't analyze it.
Fmax = low frequency
Fmax = high frequency
103
Whats an Fmax and Why Does It Matter?

Fmax is the maximum frequency of the spectrum.
If you don't collect it, you can't analyze it.
Why not always collect the highest Fmax possible?
Limitations of the analyzer
Takes extra data storage space
Reduces the resolution of the spectrum
104
Fmax = 10 orders of operating speed for general analysis,

such as Unbalance, Misalignment, ...
Fmax = 20 orders of operating speed for Blade / Vane Pass analysis,
for example; Pump, Fan, Blower...
Fmax = 50 orders for Bearing analysis for Shaft diameter less than 4-6
Fmax = 75 orders for Bearing analysis for Shaft diameter greater than 4-6
Fmax = 3.5 Times of Gear Mesh Frequency (GMF),for Gear Analysis
(GMF = Number of Gear Teeth x Shaft Running Speed of the Gear)
Fmax = 2.5 orders of Line Frequency for Electrical Eccentric Rotor/Stator,

and Electrical Phase problem
Fmax = 6KHz for Rotor Bar and Shorting Ring problem
105
106
Why should I be concerned about resolution?
Because, if you can't see it, you can't analyze it....
107
Amplitude
FREQUENCY
RESOLUTION
Number of Lines
lines or bins or cells
of resolution
Frequency
Resolution =
Fmax
Fmax
Number of Lines
108
Sampling Size = 256, 512, 1024, 2048, 4096, 8192, 16384, 32768
Resolution Line = 100, 200, 400, 800, 1600, 3200, 6400, 12800
Remark : 8 bits
256
Example : 100 Spectrum, Time Domain 2.5 Spectrum

109
Spectrum
Frequency = F max.
Resolution Line
For example : F max = 1000 Hz, Resolution Line = 400
Frequency = 1000 = 2.5 Hz.
400
Time = T max = 1 = 0.4 sec.
2.5
4 average = 4 x 0.4 = 1.6 sec
Overlap 50 % = 1.6 sec / 2 = 0.8 sec.
Additional bearing spectrum = 2 x 0.8 = 1.6 sec.
110
Resolution Line Recommendation

400 Lines for general purpose
800 Lines for Gear and Bearing analysis
3200 Lines for Motor Analysis
The example of resolution for Bearing.
Speed > 900 rpm , Resolution = 3-5 Hz per Line
Speed < 900 rpm , Resolution = 1.5-3 Hz per Line
111
Filter Type
Low Pass Filter
- LP 1000 Hz. = Cut-Off Frequency more than 1000 Hz.
Band Pass Filter
- BP 10-1000 Hz. = Cut-Off Frequency less than 10 Hz.
and more than 1000 Hz.
High Pass Filter
- HP 10 Hz. = Cut-Off Frequency less than 10 Hz.
112

1) Amplitude Unit : Displacement, Velocity, Acceleration
2) Type of Detection : RMS, Peak, Peak-Peak
3) Fmax :
The range of vibration frequencies to be analyzed
4) Frequency units : CPM or Hz
5) Filtering :
The frequency to filter out ( noise frequency )
6) Resolution Lines : The accuracy of displayed vibration frequencies
7) Number of Spectrum averages : How many FFTs are taken and
amplitude-averaged to minimize random and transient events
113
Vibration
Vibration Analysis
Analysis
Overall
Overall Value
Value Part
Part
114
Vibration Analysis
"Of all the parameters that can be measured
non-intrusively in industry today,
the one containing the most information
is the vibration signature."
Art Crawford
115

SPRING MASS SYSTEM
Plot
116
Frequency
Hz
20 mm.
Fig 1)
Velocity in mm/s = Machines Fatigue

1 cycle For Example ; the same displacement amplitude as 20mm.
1 minute
Machine can be bent as 1,000,000 times.
as Fig 1) the velocity amplitude is 20 mm/min
= 0.33 mm/s, broken in 1,000,000 min.
100 cycles
1 minute
Fig 2)
Displacement in mm = Machines Stress

For Example; 20 mm. Amplitude,
Whats it tell us? Just Stress
as Fig 2) the velocity amplitude is 20 mm/1/100 min

= 2000 mm/min
= 33.3 mm/s, broken in 10,000 min.
Acceleration in G = Impact Force from Bearing or Gear

* Rate of Change of velocity from zero to max. velocity
or max. velocity to zero, if the velocity has been changed
so fast, it means high G , as a hammer knock to a rigid
117 table
Diagnosing Machine Faults

1) Unbalance
30%
2) Misalignment
3) Resonance
30%
10%
4) Bearing defects
5) Gear defects
10%
6) Belt & Pulley problems
15%
7) Motor analysis
8) General looseness or wear
9) Soft Foot problem
5%
10) Blade / Vane pass problem

11) ETC...
118
General Machinery
Vibration
Severity Chart
119
Vibration acceleration
(Gs)
Severity chart
120
Vibration
acceleration
in Spike Energy
(GSE)
Severity chart
121
SUGGESTED OVERALL ALARMS BY MACHINE

TYPE-METRIC (PEAK, OVERALL VELOCITY, MM/SEC.)
MACHINE TYPE
COOLING TOWER DRIVES
COMPRESSORS
Reciprocating
Rotary Screw
Centrifugal with or without External Gearbox
Centrifugal-Integral Gear (Axial Meas.)
Centrifugal-Integral Gear (Radial Meas.)
BLOWERS FANS
Lobe-Type Rotary
Belt-Driven Blower
General Direct Drive Fans
Primary Air Fans
Large Forced Draft Fans
Large Induced Draft Fans
Shaft-Mounted Integral Fan
MOTOR/GENERATOR SETS
Belt-Driven
Direct Coupled
CHILLERS
Reciprocating
Centrifugal (Open-Air)
Centrifugal (Hermetic)
LARGE TURBINE/GENERATORS
3600 RPM Turbine/Generators
GOOD
0-9.5
FAIR
9.5-15
ALARM
15
0-8
0-7
0-5
0-5
0-4
8-13
7-11
5-7.5
5-7.5
4-6.5
13
11
7.5
7.5
6.5
0-7.5
0-7
0-6.5
0-6.5
0-5
0-4.5
0-4.5
7.5-11.5
7-11
6.5-9.5
6.5+9.5
5-7.5
4.5-7
4.5-7
11.5
11
9.5
9.5
7.5
7
7
0.7
0-5
7-11
5-7.5
11
7.5
0-6.5
0-5
0-4
6.5-10
5-7.5
4-6
10
7.5
6
0-6.5
0-.65
0-4.5
6.5-9.5
6.5-9.5
4.5-7
9.5
9.5
7
122
MACHINE TYPE
CENTRIFUGAL PUMPS
Vertical Pump (12" - 20")
Vertical Pump (8" - 12" Height)
General Purpose Horizontal
Boiler Feed Pumps
Hydraulic Pumps
MACHINE TOOLS
Motor
Gearbox Input
Gearbox Output
SPINDLES
Roughing Operations
Machine Finishing
Critical Finishing
GOOD
FAIR
ALARM
0-9.5
0-8
0-6.5
0-5
0-5
0-5
0-3
9.5-15
8-13
6.5-10
5-7.5
5-7.5
5-7.5
3-5
15
13
10
7.5
7.5
7.5
5
0-2.5
0-4
0-2.5
2.5-4.5
4-6
2.5-4.5
4.5
6
4.5
0-2
0-1
0-0.5
2-3
1-2
0.5-1
3
2
1
CHART NOTES :
1. Assuming machine speed = 500 to 600,000 RPM.
2. Assuming measurements by accelerometer or velocity pickup as close as possible to
bearing housing.
3. Assuming machine not mounted on vibration isolators (for isolated machinery-set alarm
30% to 50% higher)
4. Set motor alarms same as that for the particular machine type, unless otherwise noted.
5. Set alarms on individual external gearbox 25% higher than that for a particular machine
type.
123
Expect Breakdown in next one month
124
Amplitude
Amplifier ICP ( Integrated Circuit Powering )
125
Frequency Vs Amplitude accuracy example
126
Directional Analysis for Overall value

R = H or V
Machine Overhung Type
Axial
Unbalance
Pure Unbalance Main Unbalance
A < 0.3R
0.3R< A < 0.5R
Vertical
Horizontal
Misalignment
Resonance
Main Misalign.
Pure Misalignment
0.5R < A < 1R
A >R
H > 4V or V > 4H
127
Directional Analysis for Spectrum value
128
Synchronous Frequency
= 1, 2, 3,...
Sub-Synchronous Frequency =
Non-Synchronous Frequency = Synchronous Sub-Synchronous
129
Harmonics
10
11
8
7
2
3
12
12
12
11
11
12
10
10
7
11
10
A
1
Cracked at A only
Cracked at both A and B
130
Harmonic Example
Harmonic Case Study
131
Amplitude Modulating
1) Occur at only one frequency which has a varied load in a specific revolution, for example,
- Bearing frequency vary amplitude at every turning speed or FTF frequency
- Gearmesh frequency vary load at every turning speed of Gear or Pinion
- Rotor Eccentricity or Cracked vary load at Pole Pass Frequency ( Slip Frequency x No. of Pole )
2) Will make only a few pairs of side band.
1 modulating revolution
132
SIDE BAND
CG = CR
CG =/ CR
7
6
4
3
11
10
11
Phase 2
Phase 1
11
+
10
11
2
3
6
5
7
8
10
11
10
Phase 3
1
9
10
8
1
11
10
11
5
6
10
Phase 4
1
11
10
133
Side Band example at Gearbox of A Cooling Tower Fan

with a very few of sideband frequency
134
Frequency Modulating
1) Occur at Eccentric , Misalign Gear which makes rotational velocity
be none-linear in one revolution.
2) Will make many pairs of side band.
135
Side Band example at Gearbox of A Cooling Tower Fan

with high numbers of sideband frequency
136
Side Band example at Gearbox of A Gas Compressor
137
138
Beating
1) Occur at 2 frequencies have very close frequency as 5-100 cpm in normally, for example,
Motor drives a fluid coupling which may have a different frequency as only lower than 100 cpm
2) Will not make a side band, just can see a two close frequencies as only 5-100 cpm which is very
hard to see if the resolution is not enough.
1 sec
The Example
17 Hz = 1020 Cpm
1 beating revolution
18 Hz = 1080 Cpm
Diff. Frequency as 60 Cpm = 1 Hz

mean the beating will be occurred
every 1 second
139
BEATING
Beat

()
(F2-F1) Beat
5 100 RPM Time
Waveform (F1) (F2)
140
Waveform 180
Beating example at Blower with Fluid Coupling

Motor speed at 1489 , Fan speed at 1202 rpm
141
Diagnosing Machine Faults

Pairoj Vongatilug
142
Three Rules of Diagnosis

1) Each machine fault generates a specific vibration pattern.
2) The frequency of the vibration is determined by the
machine geometry and operating speed.
3) A single vibration measurement provides information
about multiple components.
143
What is Unbalance?
The force created by a rotating body when its center of mass is
offset from its center of rotation
Center of Mass = Center of Rotation
Heavy Spot
Center of Mass
Center of Shaft
Rotation
144
Unbalance /

Heavy Spot
Center of Mass
Center of Shaft
1.
Rotation
2.
3. ,
,
145
Type Unbalance
2
1. Single Unbalance ()
2. Couple Unbalance ()
3
1. Force Unbalance
2. Couple Unbalance
3. Overhung Rotor
2
Static Balance ()

Dynamic Balance
146
Unbalance
1.
2.
3.
4.
(
1
1X
(Phase)
Overhung Rotor
147
Types of Unbalance
Unbalance can be separated into 4 components:
Quasi-Static Unbalance:
Static Unbalance:
Constant phase across the rotor
Rotation
Axis
Unbalance
Center of Gravity
Rotation Axis
Unbalance
Displacement Caused
by Unbalance
Shaft Centerline
Couple Unbalance:
o
180 phase shift across the rotor

Rotation Axis
Unbalance
180o phase shift across the rotor
Center Of Gravity
Shaft Centerline
Center Of Gravity
Shaft Centerline
Dynamic Unbalance:
Rotation Axis
Unbalance
Center Of Gravity
Shaft Centerline
148
Static Unbalance:
Constant phase across the rotor
Rotation
Axis
Unbalance
Center of Gravity
Physical Diagram
Shaft Centerline
Force Diagram
Motion Diagram
149
0o phase shift or in Phase across the rotor
Rotation Axis
Rotation Axis
Center Of Gravity
Unbalance
Unbalance
Shaft Centerline
Shaft Centerline
Physical Diagram
S ( S/2 > C )
S/2
C
Center Of Gravity
S ( S/2 < C )
S/2
C S/2
Force Diagram
Motion Diagram
S/2
C
150
Couple Unbalance:
Rotation Axis
Unbalance
Center Of Gravity
Physical Diagram
Shaft Centerline
Force Diagram
C
Motion Diagram
151
Dynamic Unbalance:
Physical Diagram
Rotation Axis
Unbalance
Center Of Gravity
Shaft Centerline
Force Diagram
Motion Diagram
152
Unbalance
Characteristics:
High radial peaks at 1X shaft RPM
Low axial vibration at 1X shaft RPM
Low harmonics of shaft RPM
1X RPM sinusoidal pattern in the time waveform
Can cause other faults to appear, especially looseness
The criteria acceptance for 1X is 90% of Overall Acceptance Value
153
Unbalance
Imbalance typically appears at
the turning speed of the machine
Imbalance
154
Unbalance
Radial vibration at 1X
shaft RPM is much
more significant than
in the axial direction
Freq: 60.04 Hz
Order: 1.010
Spec: .390
155
Unbalance Case History
TOH
TOV
TOA
Turbine
Turbine has thrown a blade and is out of balance.

Speed reduced to keep vibration levels acceptable, but now
turbine cannot supply enough air to boiler to generate
sufficient steam for plant processes and heating.
TIH
TIV
TIA
Gearbox
ID Fan
156
Boiler Induced Draft Fan
Velocity in horizontal direction on turbine OB bearing
157

THE 1 X RUN SPEED PEAK
DOMINATES THE SPECTRUM
Almost all vibration is in component at 1order (2609 RPM).
158
Very Little Higher Order Activity
This spectrum is typical of imbalance problems.
159

2.
1. 3.
1. 3.
2.
1. 3.
1. 3.
1.
2.
Major peaks in radial directions all at 1 order of running speed
3.
Higher orders of 1x shaft speed have very low amplitude
Very little axial vibration on the inboard or outboard bearings
160
Unbalance
REMARKS:
Most common cause of vibration whose amplitude is proportional
to the amount of unbalance.
May be aggravated by or may produce complications such as seal
rubs, bearing failure or resonance.
Overhung rotors may show relatively high Axial Vibration
161
Ultrasonic
Very High "Squeal"
Very High Loud "Scre
High Pitch "Whine"
"Hum"
Periodic "Beat"
Loud "Roar"
(1)
Low Freq. "Rumble"
Reference Marks)
Phase ( No of
couplings
Bearings
Piping
rotor(shaft)
Foundation
Axial
10
1/4 RPM
Shaft Bow -Lost Parts
1/2 RPM
2 X RPM
1 X RPM
50-100%
40-50%
0-40%
10
(RELATIVE PROBABILITY RATINGS: 1 THRU 10)
PREDOMINANT NOISE
PROBABLE LOCATION
Vertical
DIRECT
Horizontal
Very High Freq.
Odd Frequencies
Low er Multiples
Higher Multiples
PREDOMINANT AMPLITUDE
Initial Unbalance
Causes of Vibration
UNBALANCE
PREDOMINANT FREQUENCIES
Casing
IRD Mechanalysis, Inc.

Vibration and Noise
Identification Chart
Force Unbalance
Couple Unbalance
Dynamic Unbalance
Overhung Unbalance
( 3 9 )
1 x RPM

180 1 x RPM

2
180 OB &
IB
1 x RPM

162
Spectrum 2X
163

, ,
1 x
RPM

0 180 (
()

180

1 x RPM 2 x
RPM (

164
Case History #1 , Coupling Unbalance

Adobe Acrobat
Document
Case History #2 , Centrifugal Comp. Unbalance

Adobe Acrobat
Document
Case History #3 , CT Fan Balance Correction

Adobe Acrobat
Document
Case History #4 , On Site Balance for Overhung Fan

Adobe Acrobat
Document
165
Unbalance
ISO 1940
166
167
Continued
168
Permissible residual in G-mm/Kg

or
Center of Gravity Displacement , e, in microns
Maximum permissible residual unbalance, e per , ISO 1940/1
100
500 1000
5000 10000
50000
100000 cpm
169
Example to correct Unbalance

by Polar diagram
Graphical Example
o
O : 6 Mils @ 90
0o
270o
90o
180o
Graphical Example
Goal is to drive the Vector to zero. At this
point, its angle does not matter.
0o
270o
90o
180o
Graphical Example
We are trying to find the value to cancel
out the O Vector.
270
0o
90o
180o
Two Problems
How much weight = 6 mils of vibration?
Where should it be placed?
The Solution
Add a trial weight = 6 grams at 25o
and measure the results
Trial Weight
0o
New Run = 4.5 Mils @ 210o
270o
O
O+T
180o
90o
Trial Weight Results

6 Grams at 25 degree
o
Resultant Vector from 6 grams at 25

o
= 9.1 mil (by actual measurement) at 25
0o
6 grams 25
Vector
o
270
270
O
90o
T
vector
180o
40 degree
Vibration 6 mils
9.1 mils Vibration Trial Weight

6 grams
6 mils Vibration weight
6 x 6 = 4 grams
9.1
Adding Correction Weights

The correction Weight 4 grams is added at 345 degree.
Our goal is to have vibration less than 1 mil. If we don't obtain
this goal, we will trim run the weights again.
Adding Correction Weight

4 Grams is added @ 345o
or 4 Grams is trimmed @ 165o
0o
270o
90o
180o
W/D RATIO
1-PLANE
2-PLANE
< 0.5
0-1000
RPM
> 1000
RPM
Width
Diameter
Width
0.5 to 2
0-150
RPM
>2
0-100
RPM
Diameter
Width
Diameter
150-2000
RPM or
>70% of
1st Critical
>100
RPM up to
70% of
1st181
Critical
Trial Weight = 0.1 x Rotor Mass x 9.81 x900

2
Radius x [ Speed x 3.14 ]
Rotor Mass in Grams
Radius in meters
182
1.
2.
Field Balance
Shop Balance or Machine Balance Shop
2
Soft and Hard Bearing
183
Field Balance
184
Shop Balance / Machine Balance
185
Vane Pass
vanes
The pressure output to the volute will vary as the

vanes pass depending on how exactly the vanes
line up with the outlet (volute) at any given
moment.
So with any centrifugal pump there will be a
pulsation (pressure pulse) that occurs at a
frequency equal to the number of vanes times the
speed of the pump.
volute
1x
5x
Hz
This
Thisisiscalled
calledthe
theVane
VanePass
Pass
frequency.
frequency. ItItisisalways
alwaysequal
equalto
to
the
thenumber
numberof
ofvanes
vanestimes
timesthe
the
speed
speedof
ofthe
thepump.
pump.
In
Inthis
thiscase
case
Vane
==5x
186
VanePass
Pass
5x
800
What is Misalignment?
Deviation from a common centerline during operation.
187
Misalignment ()
(Misalignment Shaft Machine)

70% Misalignment
,
188
Misalignment

Coupling
Flexible Rigid

Seal
189
Types of Misalignment
Offset
Angular
Both
190
0 degree
90 degree
180 degree
270 degree
360 degree
191
0 Degree
90 Degree
180 Degree
270 Degree
360 Degree
192
Misalignment
Characteristics:
1X shaft RPM axial dominates
High axial at 1, 2 and 3X shaft RPM
High radial at 1, 2 and 3X shaft RPM
Harmonics of shaft RPM above 4X are usually low
Phase readings show a 180o shift across the coupling
The criteria acceptance for 2X is 50% and 3X is 40% of Overall
Acceptance Value
193
SYMPTOMS OF MISALIGNMENT
Radial vibration is highly directional
1X RPM, 2 X RPM, and 3 X RPM can be present, depending on the
type and extent of misalignment
Misalignment
Angular
Parallel
Combination
Symptom
1X RPM
2 X RPM
1/2/3 X RPM
Direction
Axial
Radial (H & V)
Radial & Axial
Problems internal to the coupling usually generate a 3 X RPM vibration.

Combination misalignment may produce 1, 2, or 3 X RPM or ANY
combination of the three frequencies. The key symptom is the phase
shift across the coupling
194
Misalignment
Misalignment typically shows up
at either 1 or 2 x turning speeds
Misalignment
195
Misalignment
2X shaft RPM is dominant
location of vibration
Vane pass is due to 11
blade pump impeller
Vane Pass
Freq: 59.50
Order: 2.010
Spec: .640
196
Using Phase to Distinguish Misalignment

From Unbalance
Take phase readings across coupling.
Axial to axial 180o out of phase = misalignment.
When shafts are misaligned, the horizontal bearing-to-bearing
phase relationship is rarely similar to the vertical bearing-to-bearing
relationship on either sides of the machine.
197

From Unbalance
If the phase readings on the coupling side bearing on each machine
are essentially in phase or 180o out of phase horizontally and
vertically, it is almost certainly misalignment.
This phase relationship has other causes such as a bow in the shaft.
Please check for this condition also using a dial indicator.
198

From Unbalance
A
A-B = 180o +/- 30o
199

5 um/Cm (0.005 mm./Cm)
0.05 mm./100 mm.
200
Tolerance

Excellent Table
Accepted Table
Speed
(Rpm)
Gap or Angular
(mm.)
Offset or
Parallel
(mm.)
Gap or Angular
(mm.)
Offset or
Parallel
(mm.)
750
0.09
0.09
0.13
0.19
1500
0.05
0.06
0.07
0.09
3000
0.03
0.03
0.04
0.06
6000
0.02
0.02
0.03
0.03
201
Misalignment Case Study
202
Angular
Parallel
180
1
2
1 , 2 3

180
2 x RPM 1 x RPM
1 x RPM

(4 8 )
203

204
Misalign Bearing Cocked on Shaft

180 /

205
Misalignment
Rotor Rub(Axial)
Piping Forces
1
2
Low Freq. "Rumble"
Loud "Roar"
1 (2) Erratic 8
Phase ( No of
(1) (2) (3)

Erratic
Erratic
3
1
1/2
1/2
Erratic
Erratic
Erratic
(1) & (2)
1
1
1
REMARKS:
Misalignment appears as a large axial vibration. Use dial indicators or other methods
for positive diagnosis.
May produce friction or deflection forces which one be severe.
Looseness creates many problems. Small amount may allow violent vibration .
Looseness in bearings may be mistaken for oil whirl.
Usually accompanied by unbalance and/or misalignment.
Distortion causes vibration indirectly by generating misalignment,causing internal rubs
or uneven bearing contact.
Piping Forces & Foundation Distortion often cause resonance problems.
Rubs are characterized by the presence of many frequencies all over the spectrum
often ultra-sonic.
206
Produce "Hot Spots" resulting in bent shaft, bearing cavitation and resonance.
Ultrasonic
couplings
1
2
High Pitch "Whine"
Piping
1
3
Reference Marks)
Foundation
Casing
Bearings
5
1
Horizontal
Very High Freq.
Odd Frequencies
Lower Multiples
1/4 RPM
1/2 RPM
2
4
Very High "Squeal"
1
1
2 X RPM
Case Distortion
Seal Rub
3
5
Foundation Distortion
PROBABLE LOCATION
Periodic "Beat"
Clearance Induced Vibration
1
1
PREDOMINANT NOISE
"Hum"
MISALIGMENT
LOOSENESS
AND
DISTORTION
5
8
DIRECT
rotor(shaft)
Mechanical Looseness
Axial
Misaligment
1 X RPM
50-100%
40-50%
Causes of Vibration
0-40%
Vibration and Noise

Higher Multiples
Vertical
Some Coupling Types recommendation

Coupling Types
Recommendation peak at
Three Joint/ Jaw Coupling
Rubber or Bun Type Coupling
Shim Pack Coupling
Grid Coupling
3X
2X
2X and 6X
4X
207
208
SOFT FOOT, SPRUNG FOOT, AND

FOOT-RELATED RESONANCE
50 -75 microns tolerance
209
Soft Foot
1, 3, 4 ( 2 ) =
2, 4 ( 1, 3 ) =
3, 4 ( 1, 2 ) =
Soft foot
Soft foot
Soft foot
: 0.001 Incs,
0.025 mm. ( 0.06 mm.)
210
Soft Foot
1.
2.
3.
4.
5.
6.
Bolts Nut

Bedplate Hold Down Bolt
Flame Bearing

(Misalignment)
211
Two types of Mechanical Looseness
Multiple harmonics of running speed for Stationary Parts: 1/3,

1/2, 2/3, 1, 1-1/3, 1.5, 1-2/3, 2, 2-1/3, 2.5, 2-2/3x,...
Multiple harmonics of running speed for Rotationary Parts: 1, 2,

3, 4, 5, 6, 7, 8, 9, 10x
212
RESONANCE
NATURAL FREQUENCY ?
1st Degree of Freedom
Force
2nd Degree of Freedom

x
k , in Hz
Fn. = NATURAL FREQUENCY = 1
2p m
k = Stiffness = ,
m = mass of system =
m L, L m Fn. 213
Fn Degree

+/- 15 % Operating Speed
Fn Degree
+/- 15% OPERATING SPEED
RESONANCE
214
RESONANCE ?
1) , mass changed
2) Distortion , Stiffness changed
3) Rubber Pad,
, Stiffness and Damping

1) Mass
2) Stiffness
3) Damping system
215
Resonance Case
Study
216
Fn 3
3 Degree of Freedom
2nd Degree of Freedom
3rd Degree of Freedom
1st Degree of Freedom
217
Gear Mesh Fault

Sidebands
increase with
gear wear
Gear Wear
Gear Mesh Frequency = Number of Teeth X Shaft Speed

218
Gears
Drive 54T
Driven 27T
Vibration Amplitude
Input =1000 RPM

Output =2000 RPM
Gearmesh=54000 CPM
1x
2x
20
54x
40
60
80
Frequency (Orders)
219
100
Bearing
Bearing Failure
Failure Analysis
Analysis
220
Different Bearing Types
221
Definition of each Bearing Types

Angular Contact Ball Bearing
Deep Groove Ball Bearing
Taper Roller Bearing
Needle Roller Bearing
Spherical Roller Thrust Bearing
Cylindrical Roller Thrust Bearing
Self Aligning Ball Bearing Cylindrical Roller Bearing Spherical Roller Bearing
Needle Roller Thrust Bearing Y-Bearing
Single Direction Thrust Ball Bearing
222
Roller Bearing Faults

Four different bearing frequencies
Ball Spin Frequency
(BSF)
Fundamental Train
Frequency
(FTF)
Ball Pass Frequency
Inner Race
(BPFI)
Ball Pass Frequency

Outer Race
(BPFO)
223
FTF-BSF-OR-IR
224
Outer Race
225
Outer Race Defect
226
Inner Race
227
Inner Race Defect
228
How Bearing Faults Generate Vibration
Outer Race
Impacting
Inner Race
Impacting
229
How Bearing Faults Generate Vibration
Outer Race
Impacting
Inner Race
Impacting
Inner race signal
with modulation
230
Ball Spin
231
Ball Spin Defect Frequency = #Defective Balls x BSF

Outer Race Frequency with BSF sideband
232
CAGE-FTF
233
Cage Frequency
234
Outer Race Frequency
?
5. ?
Inner Race Frequency
?
8. ?
Ball Spin Frequency
?
2. ?
Cage Frequency
0.3 - 0.5 X
235
Bearing Data Input
236
Nb
Bd
Cos O ) x RPM
BPOR = Ball Pass Outer Race = 2 ( 1 Pd
Nb
Bd
Cos O ) x RPM
BPIR = Ball Pass Inner Race = 2 ( 1 +
Pd
Pd
BSF = Ball Spin Frequency = 2Bd 1 - ( Bd Cos O)2 x RPM
Pd
1
Bd
(
1
Cos O ) x RPM
FTF = Fundamental Train Freq. = 2
Pd
(Inner Race Rotating)
1
Bd
(
1
+
Cos O ) x RPM
FTF = Fundamental Train Freq. = 2
Pd
(Outer Race Rotating)
237
N b = Number of Balls or Rollers

Bd = Ball / Roller Diameter
Pd = Bearing Pitch Diameter
O = Contact Angle
Remember that BPOR + BPIR = Number of Balls
238
Rolling Element Bearings
N=8 (Balls)
Estimation Equations
Defect on Outer Race
Defect on Inner Race
Ball Spin Frequency
Train Frequency
.5x8 1.2 = 2.8

.5xN + 1.2 = 5.2
.2xN-1.2/N = 1.45
.5-1.2/N = .35
Vibration Amplitude
Estimation Equations
Defect on Outer Race
Defect on Inner Race
Ball Spin Frequency
Train Frequency
~.5xN 1.2
~.5xN + 1.2
~.2xN-1.2/N
~.5-1.2/N
FTF
1X
BSOR
BSF
BSIR
4
6
8
239
Frequency (Orders)
10
Pan Cake Bearing
240
Roller Bearing Faults

Bearing wear shows up at
specific peaks related to the
geometry of the bearing
Bearing Wear
241
Unit Selection
242
Onset of Outer Race Defect
Early bearing wear frequently

cant be detected with
standard vibration measurements
243
Actual Outer Race Defect
Advanced bearing wear shows

up clearly in spectrum
244
Cocked Bearing
245
Lack of Lubrication
246
Improper Lubrication & Installation
247
248
Bearing Loose in Housing

1) Truncated Waveform
2) Rubbing
-Fractional Harmonics in Spectra about 1/3 of
Running Speed
3) Operationally
-Speed Varies
4) Excitation of Resonance
249
NOTE:
Loss of Discreet Peaks indicates drastic change in the
Bearing Geometry.
The criteria acceptance for Bearing Frequencies is 30% of Overall

Acceptance Value
The criteria acceptance for Bearing Harmonic Frequencies is 25% of
Overall Acceptance Value
The criteria acceptance for Bearing Natural Frequencies is 20% of
Overall Acceptance Value
250
The vast majority of bearings are one of two types:

Rolling Element, or Anti-Friction Bearings
and Fluid Film Bearings
Accelerometer
Eddy Current Probe
bearing
bearing
housing
bearing
bearing
housing
Soft Metal
(Babbitt)
Oil Wedge
(load zone)
Fluid Film: Capable of supporting very high loads,

high temperatures, high speed. Expensive and
associated rotor dynamics are very complex.
Rolling Element: Low cost, simple to apply. But

are capable of only moderate speeds and relatively light
loads. Rotor dynamics arent bad but diagnostics can be
complex due to all those spinning balls!
251
Bearing Problems at Turning Speed Harmonics

1)
2)
3)
4)
5)
Internal Clearances
Loose Bearing Mounts
Bearing Loose in Housing
Slipping on the Shaft
Misaligned Bearing
Standard Waveform of Bad Bearing
Standard waveform
Some level of impacting visible
Standard FFT of Bad Bearing
Standard FFT
High frequency signals
252
Lubrication Problems
1) Lack of Lubrication
2) Excessive Lubrication
3) Dirty Lubrication
253
Other Causes of Bearing Failure

1) Improper Application
2) Manufacturing Defects
3) Brinelling
254
Spike Energy Review

Cracked bearing
inner race shows
clearly on gSE, not
in Overall value
255
Rolling Element Bearing Faults &

gSE Spike Energy Measurement
Using the right filter, what remains is the vibration
response to the impacts that are occurring as the balls or
rollers pass over the defect(s)
This provides a measure of the energy generated by any
impacts which equals a direct measure of:
Bearing Wear
Lubrication Issues
Improper Installation
Amplitude
Almost always the vibration energy from a

bearing fault is so small that it gets hidden
by all the other machine vibrations:
Unbalance
Looseness
Misalignment, etc.
256
How Demodulating Technique work

Step 1: High Pass Filter at 0.5 - 2.5 kHz which is
the Natural Frequency of most bearings.
257
Constant Time
T of Impact Frequency = FTF, BSF, BPOR, BPIR
Tn = 1 / Fn
Fn = Natural Frequency
Tn
Step 2 : Resonance the shock pulse

Step 3 : Enveloping
Step 4 : Demodulate the high freq.
258
to low impact frequency
DEMODULATION
259
Bad Bearings and Journal
Unequal Brg. Stiff Horiz/Vert
9 @ CR
Erratic
Erratic
Erratic
Changing
Ultrasonic
Very High "Squeal"
High Pitch "Whine"
(1)
Periodic "Beat"
"Hum"
couplings
Piping
Foundation
Low Freq. "Rumble"
Reference Marks)
Phase ( No of
Very High Freq.
Odd Frequencies
Low er Multiples
1/4 RPM
Loud "Roar"
10
1/2 RPM
Bearings
Bearing Excited Vibration
rotor(shaft)
PROBABLE LOCATION
Axial
Thrust Brg. Damage
DIRECT
PREDOMINANT NOISE
Vertical
Radial Bgr. Damage
Horizontal
BAD BEARINGS
AND
JOURNALS
2 X RPM
Journal & Bearing Eccentric
1 X RPM
50-100%
40-50%
Causes of Vibration
0-40%
Vibration and Noise

Higher Multiples
Casing
3
6
REMARKS:
In the case of anti-friction Bearing failures, very high frequencies will
be noted with the bearing responsible being the one at the point of
the largest in line with gear centers.
On motors or generators vibration disappear when power is turned off.
On pumps and blowers, improvement may be accomplished by
balancing.
Velocity measurements are recommended when analyzing for
260
Anti-friction bearing failures.
Case History #1 , Bearing Inner Race Defected

Adobe Acrobat
Document
Case History #2 , Bearing Outer Race Defected

Adobe Acrobat
Document
Case History #3 , Pump Bearing Defected

Adobe Acrobat
Document
Case History #4 , CT Water Pump Failure

Adobe Acrobat
Document
Case History #5 , HVAC Fan Bearing Damage

Adobe Acrobat
Document
261
Case History #6 , Bearing Lubrication Lack

Adobe Acrobat
Document
Case History #7 , Motor Bearing DE Failure

Adobe Acrobat
Document
Case History #8 , Motor Bearing NDE Failure

Adobe Acrobat
Document
Case History #9 , Motor Pulley Drive Bearing Failure

Adobe Acrobat
Document
262
:
1 : (Ultrasonic Frequency) 20-60
(1,200,000 3,600,000 /) Spike Energy (gSE), HFD (g) shock pulse (dB)
Spike Energy 0.25 gSE 1 (
)
2 : (fn.) 30,000 120,000

/ (Sideband) 2 Spike Energy (
0.25 gSE 0.5 gSE)
263
3 : ()

Spike Energy ( 0.5 1 gSE)

4 :

Noise Floor Spike Energy
Spike Energy
264
JOURNAL BEARINGS
1X
2X
3X
4X
Radial
5X
6X
7X
0.5X
Raised Noise Floor indicating Clearance / Looseness
Wear / Clearance Problems

Radial
Oil Whirl Instability
( 10 20
)

0.42-0.48
50%
(
)

,
265

Steps in Developing
a Conditioned Based Maintenance Program
Program Audit/Assessment
Equipment Survey
Prioritizing equipment
CbM Technique Selections
Select Surveillance Intervals
CbM Equipment Selections
Personnel Selections
Decisions on how to integrate
into site maintenance and
operations
Work Requests, Planning
and Scheduling
Work Acceptance and
History
Personnel Training
Database Setups
CbM Database
Equipment Database
Establish Equipment Limits
Establish Baselines
Routine Data Collection
In-depth Analysis
Correct Machinery Faults
Program Justification
266
Step 1: Define Program Focus
Identify Critical Machines

Effect on production
Availability of back-up machine
Cost to repair
Time to repair
For Example:
Class A ( Critical Machines) mean Plant Shutdown and no Standby
unit. Lost in both Production Time, Quality, Reliability, Scrap for
start-up and Waiting Time for spare unit.
Interval Time = 2
weeks.
Class B (Necessary Machines) means Plant Shutdown but there are
Standby units. Lost in Production Time, Quality, Reliability,
Scrap for start-up and etc. Interval Time = 4 weeks.
Class C (Balance of Plant) means no Plant Shutdown, and there are
Standby units, but lost in Production Speed, Quantity, Quality,
Reliability and etc. Interval Time = 3 months.
267
Step 2: Determine Collection Methods
Route-based periodic
general plant equipment
walk around survey
manual measurement
monthly reading typical
readily accessible
Online monitoring
critical equipment
installed sensors
automatic monitoring
define measurement
interval
inaccessible or hazardous
area
268
Step 3: Create Database
Enter machine information

Machine ID (asset code)
Description
Operating speed (RPM)
Define measurement points
Point ID (identification)
Description
Sensor type (accelerometer)
Analysis Parameters (how to analyze signal)
Alarm Limits (allowable amount of vibration)
269
Measurement Point Locations

MOH
MOV
MIH
MIV
PIH
PIV
POH
POV
POA
MOA
2 per bearing + 1 axial measurement per shaft
270
Choose measurement locations
Select optimum locations. For

acceleration and ultra-sonic rolling
element bearing detection get as close
to the machine bearings as possible
(ideally within load zone).
If you have to compromise on safety or
frequency response consider installing
a permanently mounted transducer
Never compromise safety.
Measure as near as possible to the
vertical & horizontal centerlines.
Axial measurements as parallel to the
shaft as possible - same location.
Do not mistake seal locations for
bearing locations e.g. on pumps
Avoid measurements on locations with a
low dynamic resistance e.g. protective
covers
271
Use a consistent naming convention
Number from the DE of prime mover to the NDE of driven unit.

Option 1
Option 2
Motor Outboard Bearing (Non drive end)
MOV
Motor Inboard Bearing (Drive end)
MIV
Fan (Driven) Inboard Bearing
FIV
Fan (Driven) Outboard Bearing
FOV
Location on the Machinery
272
3120
MACHINE IDENT: 3 COND XFER PUMP
DRIVER
RPM min: 2970
max.:
MFGR:WESTINGHOUSE
MODEL: 7209
SER NO.:
V 480 P 3 A 109
pulley: ___ID
INTERMEDIATE
AREA: NGS-3
ROUTE:
DRIVEN
RPM min.: 2970
max.:
RPM in:
out:
RATIO:
MODEL:
SER NO.:
RATING:
BELT #:
MFGR:WESTINGHOUSE
MODEL:
SER NO.:
RATING:
# BLADES:
BRG#: BALL 6312 (I)
BRG#:
(I)
BRG#: BALL
(I)
BRG#: BALL 6312 (O)
BRG#:
(O)
BRG#: BALL
(O)
H.P.: 100
OTHER:
GEAR T:
OTHER:
CT
GEAR T:
OTHER:
CT
273
Step 4: Collect Data

Accurate vibration data is collected in a route mode
Analyzers, data collectors and continuous monitoring
systems
Database is built in the computer
May need to trend parameters other than vibration
Establish alarm and warning levels
From experience
From manufacturers recommendations
Published Corporate Specifications
Vibration Severity Charts
Overall Alarm Charts
274
DETECTION - THE VIBRATION TRANSDUCER

The Heart of Every Vibration Instrument
Converts Mechanical Vibration Energy into an equivalent
Electrical Voltage Signal
Different transducers detect:
Displacement (Eddy-Current or proximity probes)
Velocity (Velocity Pickup or Velometer)
Acceleration (Accelerometer)
Accelerometers are the most common
All parameters can be obtained (displacement and velocity
through integration )
Can be made fairly cheaply / rugged
Not affected by mounting direction or shaft runout
275
COMPRESSION ACCELERATION TRANSDUCER
276
MOUNTING MAKES A DIFFERENCE
277
ANALYSIS - EVALUATE BASED ON:

How Do We View These Measured Items?
Trend
Spectrum Graphs (Frequency Domain)
Time Waveform (Time Domain)
Waterfall Diagram Or Plot
278
TYPICAL TREND
279
Overall Alarm
Area (energy) under the spectrum
'Shotgun' method
No diagnostic information
Bearing and gear problems will not provide early warning with
overall alarm
ALARM LEVEL = 0.1 IN/SEC
PEAK - RMS
OVERALL VALUE
280
Overall Alarm
Total vibration on machine
PEAK - RMS
OVERALL VALUE
May detect imbalance vibration

(typically higher amplitudes)
281
Overall Alarm
Total vibration on machine
PEAK - RMS
OVERALL VALUE
Not sensitive enough for even advanced bearing faults

(typically low amplitude signals)
282
Frequency Bands
Divide spectrum into frequency bands based on the
types of mechanical faults that might appear on the machine.
1X
Imbalance
2X
Misalignment
3X-Looseness
6X
BEARING
BAND
Bearing Band
1 1
BEARING
BAND
Bearing Band
2 2
9-30X RPM
30-50X RPM
283
Frequency Bands
1X
Imbalance
2X
Misalignment
3X-Looseness
6X
BEARING
BAND
Bearing Band
1 1
BEARING
BAND
Bearing Band
2 2
9-30X RPM
30-50X RPM
284
Frequency Bands
1X
Imbalance
2X
Misalignment
3X-Looseness
6X
BEARING
BAND
Bearing Band
1 1
BEARING
BAND
Bearing Band
2 2
9-30X RPM
30-50X RPM
285
Frequency Bands
1X
Imbalance
2X
Misalignment
3X-Looseness
6X
BEARING
BAND
Bearing Band
1 1
BEARING
BAND
Bearing Band
2 2
9-30X RPM
30-50X RPM
286
Frequency Bands
1X
Imbalance
2X
Misalignment
3X-Looseness
6X
BEARING
BAND
Bearing Band
1 1
BEARING
BAND
Bearing Band
2 2
9-30X RPM
30-50X RPM
287
Frequency Bands
1X
Imbalance
2X
Misalignment
3X-Looseness
6X
BEARING
BAND
Bearing Band
1 1
BEARING
BAND
Bearing Band
2 2
9-30X RPM
30-50X RPM
288
Frequency Bands With Trend

Amplitude
SubHarmonic
1X
1xRPM
0.3
in/sec
2X
Bearing
2xRPM
Bearing
Gears
Bearing
10-20xRPM
Trend of
Imbalance
Trend of
Bearing Wear
Time
(Days)
0.1
in/sec
Alarm
Time
(Days)
289
Envelope Alarming
Constructed from baseline spectra
"Variable-shape enveloping"
Effective in finding small changes
290
Example of Narrow Band Alarming
291
INTERPRETING THE DATA
Identify the machine component with the vibration

problem (motor, pump, gears)
In most (not all) cases the problem component will
have the highest amplitude
In cases that have a common problem frequency,
amplitude and phase must be used
Reduce the number of possible problems from several
hundred to only a few
292
OVERVIEW OF THE MOST COMMON PROBLEMS
Unbalance
Bent Shafts
Misalignment
Looseness
Eccentricity
Problems
Resonance
Belt Drive
Problems
Defective Rolling
Element Bearings
Sleeve Bearing
Problems
Electric (Induction)
Motor Problems
Gear Problems
293
Step 6: Getting to the Real Problem

500 Total
Machines
200 From
Screening
100 From
Expert System
50 Real
Problems
294
Remembers
Thank you for your join our training course.
Hope you all can help improvement your plants
productivity in the near future to make your plant
more profitability.
please remember that its just not only vibration
It must be Learning, Training, Experiencing.
It still need Total Productive Maintenance,
Operator, Maintenance and Inspection team
have to work together to get a co-analysis
Finally, it also need other analysis tools, such as
Oil and Current Analysis to integrate in one system
295
to fast and deep analysis of machine health
.
VIBRATION OVERALL SPECTRUM

1) OVERALL
-
-
-
-
- , , LOAD,

2) SPECTRUM
- (ROOT CAUSE)
- LOAD

-
-
-
-
296

SPECTRUM OVERALL OVERALL FRONT CHECK
SPECTRUM
1) OVERALL
SPECTRUM
2) SPECTRUM

SPECTRUM
OVERALL 5-10 , OVERALL
1-2 20%
() SPECTRUM
3)
4) VIBRATION DATALOGGER

5) PEAK SPECTRUM
6) VIBRATION 70%
297
1)
SENSOR
2)

,
, ,
,
3)

1) 10,000
20,000
298
1)
1) ,
, H 2
2) GEARBOX COOLING TOWER

I-BEAM GEARBOX
-
, PRESSPART

- COMPRESSOR

- , ,

- BEARING HOUSING COVER SAFEGUARD

SCREENER
BEARING HIGH SPEED SHAFT RAW MILL TABLE
299

LOAD COOLING TOWER
ROLLER FELT DRYER PART
HYDRAULIC FORCE
BLADE PASS COOLING FAN AERODYNAMIC
FLOW BLADE PASS
(AERODYNAMIC),
NIPPING NIP ROLL
300
SENSOR 4
1) SENSOR OUTPUT RELAY VIBRATION SWITCH
2) SENSOR BNC SPECTRUM
TRAP
3) SENSOR MONITOR VIBRATION
4-20 mA DCS, PLC
VIBRATION OVERALL
4) SENSOR ONLINE SPECTRUM
ONLINE
301
A2
A1
302
1) VIBRATION SWITCH
303
1) VIBRATION SWITCH
1) 3 4
2 30,000 - 50,000
2) RELAY

1) 2
2) VIBRATION
SENSOR
3)
SPECTRUM ROOT CAUSE
4) VIBRATION SWITCH
SENSOR 20
( 1- 2 )
5) SENSOR
SENSOR SWITCH VIBRATION
SWITCH
D ISPLAY STANDARD
SHAKER
6) ALARM TRIP
(TRIP
) (TRIP )
304
2) SENSOR BNC
305
Sensors and Wiring

Select sensor
Wire to machine
Use portable
306
307
2) SENSOR BNC
1) 10,000 - 20,000
2) BNC OUTPUT SPECTRUM TRAP
OVERALL ROOTCAUSE
3) SPECTRUM SENSOR
BIAS
VOLTAGE
4)
1)
SPECTRUM
VIBRATION

2) VIBRATION

VIBRATION
SPECTRUM
3) OPERATOR PM VISUAL INSPECTION
VIBRATION ROUTE
PM
4) ALARM TRIP RELAY
5) SPECTRUM
6) VIBRATION
308
3) SENSOR MONITOR OUTPUT RELAY,

4-20 mA OUTPUT BNC CONNECTOR
309
New Online Monitoring and Protection system for Cooling Tower for $1000 per Cell
1) LCD Display for every channels.
2) Adjustable alarm of A1 and A2, Fault alarm.
3) 4-20 mA output to PLC or DCS.
4) Buffer BNC Output for analysis by portable data collector.
5) market sensors at very low cost as only $200 per one sensor.
310
3) SENSOR MONITOR OUTPUT RELAY,

4-20 mA OUTPUT BNC CONNECTOR
1) VIBRATION OPERATOR PM VIBRATION

ROUTE GENERAL/VISUAL INSPECTION
2) VIBRATION
3) RELAY VIBRATION SENSOR RELAY 3 TRIP
4) MONITOR SPECTRUM Trap

5) PM VISUAL INSPECTION
6) 4-20 mA PLC, DCS RECORDER PLOT
PM OPERATOR VIBRATION
INSPECTION
SCAN VIBRATION
7) BNC CONNECTOR TRAP SPECTRUM BASE LINE ROOTCAUSE
8) VIBRATION
9) ALARM TRIP DIGITAL
, ISO STANDARD
1) 40,000 - 60,000 SENSOR
311
4) SENSOR ONLINE
SPECTRUM ONLINE
312
Online Monitoring
313
4) SENSOR ONLINE
SPECTRUM ONLINE
1) SENSOR 3)
SPECTRUM ONLINE
SPECTRUM
1) SENSOR
60,000 -80,000 ( 16 )
314

999/7 Soi Anamai, Suanluang, Suanluang, Bangkok 10250 Tel. 02-7214191-2 Fax. 02-7214190 Contact: MR - Kosin Jitjaturunt Mobile: 66-81-5837797

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999/7 Soi Anamai, Suanluang, Suanluang, Bangkok 10250

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Vibration Excitation Sources

Journal (Fluid Film)

Vibration vs. Machine Life

L Life (Hours) = 16,666 x Rate

L10= Bearing Life Time in Running hours.

Centrifugal Fan Rotor

From the above Equation,

Dynamic Load Vibration

f = Frequency in Hz., (next page for detail)

= 0.01 mr ( rpm / 1000 )

W = 0.01 x 1,650 ( 1485 / 1000 )

From the previous Equation

the expected life time is about 72,686 Hours

BREAKDOWN Case Study

Time Base Case Study ( )

Time Base Case Study ( )

Subjective Maintenance Case Study

CbM Program Advantages:

Allows machines in good operating condition to continue to run

Vibration CbM Program

ISO 2372 Criteria

Remark : 1) Amplitude in mm/s

ISO 10816 Part 3

Limit, mm/s, rms

Medium Size Machines

160 mm < Motor Height < 315 mm

ISO 10816 Part 3

Limit, micron, rms

Medium Size Machines

160 mm < Motor Height < 315 mm

Vertical Pump Case

Measurement Point Locations

2 per bearing + 1 axial measurement per shaft

Amplitude Units What You See

mils (0.001 inch)

What's the difference?

For Pure Sine Wave Form

*The Tacho signal get

Phase Measured between

Phase Measured between the

Phase Measured between the

180o Out of Phase:

180o Out of Phase:

180o Out of Phase:

All sensors are designed to measure one of the three

Sensors & Units

mils (0.001 inch)

Velometers & Integrating

, NCPU (Non Contact Pickup Unit)

Eddy Current Probe

Theory of Operation - NCPU

Theory of Operation - NCPU

Average Gap Voltage

Monitor Turbine, Compressor,

UNIT IN RELATIVE VIBRATION

Example of Certification of Calibration

EDDY PROBE CALIBRATION REPORT

Date of Test: 16/09/02

Calibrated Probe P/N: 1909/30/05/1/05

Probe position: G-DEX

Calibration Equipment : TK3