Vibration Analysis Services

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 What is Vibration?

Vibration is the movement of a body about its reference position.

Vibration occurs because of an excitation force that causes motion.

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 Vibration Terms

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 Time Waveform Analysis

q.
f re
h
hig

y
e nc
overall vibration tim qu
e q. fre
fre
low

Individual vibration signals

combine to form a complex
time waveform showing overall
vibration

complex time waveform

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 Overall Vibration
z The total vibration
energy measured
within a specific
frequency range.
– includes a combination
of all vibration signals
within measured
frequency range
– does not include
vibration signals outside
measured frequency
range
– produces a numerical
value

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 Amplitude vs. Frequency
– Vibration amplitude indicates the severity of the problem.
– Vibration frequency indicates the source of the problem.

1X
amplitude

3X
2X

4X

frequency

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 Vibration- Measurable Characteristics
Velocity is the first derivative of displacement as a function of time, it is the rate
of change in displacement (the speed of the vibration).
Acceleration is the second derivative of displacement, it is the rate of change of
velocity (the change in speed of the vibration).

0 90 180 270 360

Acceleration Velocity Displacement

Time

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 Scale Factors
– When comparing overall vibration signals, it is
imperative that both signals be measured on the
same frequency range and with the same
scale factors. NOTE: RMS is .707 of peak.

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 Measurements & Units
Displacement (Distance)
mils or micrometer, mm
Velocity (Speed - Rate of change of displcmt)
in/sec or mm/sec
Acceleration (Rate of change of velocity)
G’s or in/sec2 or mm/sec2

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 Lines of Resolution
Individual Vertical Lines or Bins Located Adjacent to One Another
Along the Frequency Axis. Each Bin is used to Store Individual Amplitude
at a Specific Frequency Location.

7200 CPM
7200 CPM
3570 CPM

3570 CPM
Amplitude
Amplitude

Frequency in CPM Frequency in CPM

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 Accelerometers

• Rugged Devices
• Operate in Wide Frequency
Range (Near 0 to above 40 kHz)
• Good High Frequency Response
• Some Models Suitable For High
Temperature
• Require Additional Electronics
(may be built into the sensor housing)

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 Velocity Sensors

• Often Measure Bearing

Housings or Machinery Casing
Vibration
• Effective in Low to Mid
Frequency Range (10 Hz to
around 1,500 Hz)
• Self Generating Devices

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 Displacement Probe/Eddy Probe
• Measure Relative
Distance Between
Two (2) Surfaces
• Accurate Low
Frequency
Response

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 Multi-Parameter Monitoring
Same Data in Velocity and Acceleration
- Model 32L S/N AB10099P FES Model 32L S/N AB10099P
#2 West -C3H Compressor Inboard Horizontal #2 W est -C3H Compressor Inboard H orizontal
0.40 5
Route Spectrum Route Spectrum
06-Feb-01 14:02:05 06-Feb-01 14:02:05

OVRALL= .6123 V-DG OVR ALL= .6123 V-DG

0.32 PK = .6091 4 PK = 8.19
LOAD = 100.0 LOAD = 100.0
RPM = 2990. RPM = 2990.

PK Acceleration in G-s
RPS = 49.83 RPS = 49.83
PK Velocity in In/Sec

Reference Env/Prf-Std Reference Env/Prf-Std

0.24 3

0.16 2

0.08 1

0 0
0 40 80 120 160 200 240 0 40 80 120 160 200 240
Frequency in kCPM Frequency in kCPM

On the same bearing, low

freq. events (imbalance,
Velocity misalignment, etc.) show Acceleration
Spectrum best in the velocity
spectrum; while high freq.
Spectrum
events (bearing faults,
gearmesh) show best in the
acceleration spectrum

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 Sensor Relationships
100
Displacement (mils)
10 Acceleration
(g's)

Amplitude
1.0
(mils, in/sec, g’s) Velocity (in/sec)

0.1
Common Machinery
1 Operating Range
0.01
10 100 1,000 10,000
Frequency (Hz)

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 Resonance

typically 10% or greater

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 Detection vs. Analysis
z Detection
Alarm limits are established for each measurement.
When the measurement’s value exceeds its
programmed alarm limits, the predictive maintenance
software or data collector notifies the analyst of a
problem.

z Analysis
Once detected, analyzing exceptional measurements
provides insight to the problem itself, and to its root
cause.

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 Important Frequency Peaks
Rotational Speed or Even Multiples
Always present but excessive amplitude or multiple
harmonics can indicate a problem.

Electric motors always have frequency peaks at shaft

rotational speed and at line frequency i.e. 60 Hz.
Two pole motors will always display a 2X line frequency
peak.

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 Important Frequency Peaks

Gas Pulsation Frequencies

Screw compressors - gas pulsation frequency(cpm) occurs at
[No. of lobes on male rotor] X [ rotational speed (RPM)]
Pumps or fans - fluid pulsation frequency(cpm) occurs at
[No. of vanes, lobes or blades] X [ rotational speed (RPM)]

Recip. Compressors - gas pulsation frequency (cpm) occurs

at [No. of pistons] x [ rotational speed (RPM)]

Harmonics or even multiples (2X and 3X) of gas pulsation

frequencies always present and are most noticeable on oil
separator vessels.

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 Setting Up the Measurement
z Physical Considerations
– Selecting the Machinery
– Selecting Measurement Planes
– Selecting Sensor Locations
– Surface Preparation
– Sensor Mounting Techniques

z Database Considerations
– Parameters (multi-parameters)
– Alarm Limits
– Setting Fmax
– Scale Factors

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 Selecting the Machinery
Critical - If a failure or shutdown occurs,
production is stopped, or machine
performance creates an unsafe environment

Essential Spared - If a failure or

shutdown occurs, production is disrupted

Non Essential Spared - If a failure

or shutdown occurs, production loss is
inconvenienced, however, a spare unit can
be brought on-line, or a repair can bring the
production unit back on-line without
significant loss of production

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 Thinking
Ahead
z Walk Through
z Machinery Data
Sheets

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 Measurement Planes

z radial
– vertical
– horizontal
z axial

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 Sensor Location
(qualifying and identifying)
Measurement POINT numbering
follows flow of power:

Motor Non-Driven End (NDE)

Motor Driven End (DE)
Compressor Driven End (DE)
Compressor Non-Driven End (NDE)

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 Sensor Location

The accelerometer must be located over the bearing of interest. Avoid air gaps
in housings whenever possible. Air gaps will skew vibration readings.

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 Sensor Location

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 Mounting Methods

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 Hand-held/Probe Mounting

Rapid and
convenient.
Subject to
many sources
of error.
Use only as a
last resort.

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 Types of Alarms
z Overall Vibration Limits
z Spectral Enveloping
z Spectral Bands
z Phase Alarms

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 Acceptable Vibration Levels
Tables are published that show overall vibration levels as a
function of rotational speed or vibration frequency for the
purpose of determining whether vibration levels are acceptable.
As a general rule for compressors operating at 3600 RPM an
overall vibration level of 0.3 ips RMS would be cause for concern

For piping and valves overall readings exceeding 1.0 ips RMS
would be cause for concern though actual stress values induced
by the vibration may be quite low and no corrective action
needed. Some engineering evaluation should be conducted to
determine this.

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 ISO Guidelines

ISO 2372
overall
velocity
vibration
guidelines

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 velocity - in/sec (peak)
Assessing
Overall

acceleration - Gs (peak)
Vibration
Severity

Frequency - CPM

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 Overall Vibration Trend Plot
VIB - Alignment Fault
ALIGNMENT -M1H MOTOR OUTBOARD BRG. - HORIZONTAL
0.24
Trend Display
FAULT of
0.20 OVERALL VALUE
PK Velocity in In/Sec

0.16
-- Baseline --
Value: .06350
0.12 Date: 11-AUG-95

0.08 ALERT
WARNING

0.04

0
0 100 200 300 400 500
Days: 11-AUG-95 To 11-DEC-96

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 Spectral Enveloping
VIB - Balance Fault
BALANCE -M2A MOTOR INBOARD AXIAL
0.40
Route Spectrum
0.35 14-MAR-96 12:10:26
PK Velocity in In/Sec

0.30 OVRALL= .3260 V-DG

PK = .3257
0.25 LOAD = 100.0
RPM = 1777.
0.20 RPS = 29.62
alarm is triggered
Reference Envelope
0.15

0.10

0.05

0
0 400 800 1200 1600 2000
Frequency in Hz

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 Phase Alarms
A2 - Machine #6 (Various Setups)
MACH#6 -PPH PEAK PHASE DATA
0 Correlation
Display

Phase
vs
Peak

Data Period:
26-Dec-96
To
28-Dec-96
2.500

90 270

180

Peak

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 Acceptable Vibration Levels
Motor
Motorand compressors
and compressors with sleeve
with bearings
sleeve do not
bearings lendlend
do not
themselves
themselveswell
wellto to
readings
readingswith accelerometers
with accelerometers andand
for for
dependable
dependable information
information a device
a device such
such as aasproximity
a proximity probe
probe
should
should bebe used
used to to measure
measure vibration
vibration in mils
in mils displacement.
displacement.
Probes should be oriented in two planes 90 ° apart and
Probes should be oriented in two planes 90 ° apart and
displacement cannot exceed the shaft to bearing clearance.
displacement cannot exceed the shaft to bearing clearance.

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 Acceptable Vibration Levels
For Individual spectrum peaks limits are set by their perceived
For Individual
cause but somespectrum peaks are
general limits limits are set
shown by their perceived
below:
cause but some general limits are shown below:

Compressors:
Compressors:
Rotational
Rotational speed
speed 1X,1X,
2X, 2X,
3X 3X 0.25 ips
0.25
RMSips RMS
Gas
GasPulsation
Pulsationat compressor
at compr. 0.27 ips RMS
0.27 ips RMS
Bearing fault frequencies 0.15 ips RMS
Bearing fault frequencies
Roller bearings (2000-3000 Hz) 2.5 g’s
0.15 ips RMS
Roller bearings (2000-3000 Hz) 2.5 g’s

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 Motors:Acceptable Vibration Levels
Rotational Speed 1X, 2X, 3X 0.25 ips RMS
Line Frequency 1X, 2X
Motors: 0.13 ips RMS
Bearing faultSpeed
Rotational frequencies
1X, 2X, 3X 0.15
0.25 ipsips RMS
RMS
Line Frequency 1X, 2X 0.13 ips RMS
Bearing fault frequencies 0.15 ips RMS

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 Readings-How Often?
•At start up - Baseline
• At start up - Baseline
•Six
• Six months after start
months after startupupunless
unlessaaproblem
problemis is suspected.
suspected. After
After
that
thatevery
every66month
month to
to one year after
one year afterthat
thatunless
unlessaadeteriorating
deteriorating
trend
trendisisobserved.
observed.
• At 25000
•At 25000 hours
hours readings
readingsshould
shouldbebetaken
takenevery
every three months
three months
totoextend
extendthe
thetime
time before
before an
an internal
internalinspection
inspectionisisrequired.
required.
•Anytime an unusual
• Anytime an unusualnoise
noiseororvibration
vibration is
is noticed.
noticed.

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 Spectrum Analysis Techniques
z Collect Useful Information
z Analyze

500 HP/3570 RPM

Motor Model 23LE

C3 C4

M1 M2 C1 C2

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 Spectrum Analysis Techniques
Some compressors have a combination of sleeve
bearings and ball thrust bearings that require different
analysis techniques.

FES Model GL Series Compressors

Thrust and
Sleeve
Bearing
Location

Sleeve Bearing Location

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 Sleeve Bearing Wear Pattern

Latter stages of journal bearing wear are normally evidenced

by presence of whole series of running speed harmonics (up to
10 or 20). Wiped journal bearings often will allow high vertical
amplitudes compared to horizontal, but may show only one
pronounced peak at 1X RPM. Journal bearings with excessive
clearance may allow a minor unbalance and/or misalignment to
cause high vibration which would be much lower if bearing
Source: Technical Associates Inc.
clearances were set to specifications. Illustrated Vibration Chart

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 Why Do Bearings Fail?
Inadequate Lubrication
- too much
- too little
- contaminated
Excessive Load
Caused by:
- misalignment
- imbalance
- bent shaft
- etc.....
Improper Handling or
Installation
Spall On Outer Race
Age

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 Typical Bearing Failure Rate

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 Bearing Defect Frequencies
BPFO
Ball Pass Frequency Outer Race
BPFI
Ball Pass Frequency Inner Race
BSF
Ball Spin Frequency
FTF
Cage Frequency or
Fundamental Train Frequency

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 Bearing Failure Stages
Stage 1 Stage 2
No apparent change on typical velocity spectrum Defect’s harmonic frequencies appear

defect’s “fund.” defect’s “harmonic”

frequency range frequency range

Stage 3 Stage 4
Defect’s fundamental frequencies also appear Defect’s harmonic frequencies develop multiple
and may exhibit sidebands sidebands (haystack), fundamental freqs. grow
and also develop sidebands

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 Sidebands
VIB - Alignment Fault
ALIGNMENT -M2H MOTOR INBOARD BRG. - HORIZONTAL
0.14
Route Spectrum
0.12 01-AUG-96 15:15:26
RMS Acceleration in G-s

OVRALL= .0665 V-DG

0.10 RMS = .2506
LOAD = 100.0
0.08 RPM = 3606.
RPS = 60.10
0.06

0.04

0.02

0
Freq: 2634.6
0 1000 2000 3000 4000
Ordr: 43.84
Frequency in Hz Spec: .02417
Dfrq: 120.19

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 Harmonics
VIB - Alignment Fault
ALIGNMENT -M2H MOTOR INBOARD BRG. - HORIZONTAL
0.06
Route Spectrum
01-AUG-96 15:15:26
0.05
PK Velocity in In/Sec

OVRALL= .0665 V-DG

PK = .0660
0.04
LOAD = 100.0
RPM = 3606.
0.03 RPS = 60.10

0.02

0.01

0
Freq: 57.69
0 1000 2000 3000 4000
Ordr: .960
Frequency in Hz Spec: .02572

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 Waterfall Plot
VIB - Alignment Fault
ALIGNMENT -M2H MOTOR INBOARD BRG. - HORIZONTAL
0.05
Max Amp
.0456
PK Velocity in In/Sec

0
11-DEC-96
21-NOV-96

28-OCT-96

30-SEP-96
01-AUG-96
05-SEP-96 15:15:26
RPM= 3550.
01-AUG-96
Freq: 57.69
0 1000 2000 3000 4000
Ordr: .975
Frequency in Hz Sp 1: .02589

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 Stator problems generate high vibration at 2X line frequency (2FL). Stator
eccentricity produces uneven stationary air gap between rotor and stator
which produces very directional vibration. Differential Air Gap should not
exceed 5% for induction motors and 10% for synchronous motors. Soft foot
and warped bases can produce an eccentric stator. Loose iron is due to
stator support weakness or looseness. Shorted stator laminations can cause
uneven, localized heating which can distort the stator itself. This produces
thermally-induced vibration which can significantly grow with operating time
causing stator distortion and static air gap problems.
Source: Technical Associates Inc.
Illustrated Vibration Chart

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 Eccentric Rotors produce a rotating variable air gap between the rotor and
stator which induces pulsating vibration (normally between 2FL and closest
running speed harmonic). Often requires "zoom" spectrum to separate 2FL
and running speed harmonic. Eccentric rotors generate 2FL surrounded by
Pole Pass frequency sidebands (FP), as well as FP sidebands around running
speed. FP appears itself at low frequency (Pole Pass Frequency = Slip
Frequency X #Poles). Common values of FP range from about 20 to 120 CPM
(0.3 - 2.0 Hz). Soft foot or misalignment often induces a variable air gap due
to distortion (actually a mechanical problem; not electrical).
Source: Technical Associates Inc.
Illustrated Vibration Chart

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 Broken or Cracked rotor bars or shorting rings; bad joints between
rotor bars and shorting rings; or shorted rotor laminations will
produce high 1X running speed vibration with pole pass frequency
sidebands (FP). In addition, these problems generate FP sidebands
around the second, third, fourth and fifth running speed
harmonics.
Source: Technical Associates Inc.
Illustrated Vibration Chart

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 Loose or open rotor bars are indicated by 2X line frequency (2FL) sidebands
surrounding Rotor Bar Pass Frequency (RBPF) and/or its harmonics (RBPF =
Number of Bars X RPM). Often will cause high levels at 2X RBPF, with only a
small amplitude at 1X RBPF. Electrically induced arcing between loose rotor
bars and end rings will often show high levels at 2X RBPF (with 2FL
sidebands); but little or no increase in amplitudes at 1X RBPF.
Source: Technical Associates Inc.
Illustrated Vibration Chart

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 Phasing problems due to loose or broken connectors can cause excessive
vibration at 2X Line Frequency (2FL) which will have sidebands around it
spaced at 1/3 Line Frequency (1/3 FL). Levels at 2FL can exceed 1.0 in/sec if
left uncorrected. This is particularly a problem if the defective connector is
only sporadically making contact. Loose or broken connectors must be
repaired to prevent catastrophic failure.
Source: Technical Associates Inc.
Illustrated Vibration Chart

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 Dosk - RAM 700 HP Motor Test1
RAM TEST 1-M2L Mot. Inboard Horiz./2X Line Freq
0.40
Route Spectrum
10-Apr-01 08:20:35

OVRALL= .3045 V-DG

0.32 PK = .3028
LOAD = 100.0
RPM = 3579.
RPS = 59.64
Reference Env/Prf-Std
PK Velocity in In/Sec

0.24

0.16

0.08

0
Freq: 7200.0
0 8000 16000 24000
Ordr: 2.012
Frequency in CPM Spec: .283

The 2x Line frequency on this motor is .283 in/sec.

this indicates a stator eccentricity problem.
The spectrum was taken at 6400 lines of resolution.

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 Dosk - RAM 700 HP Motor Test1
RAM TEST 1-M2L Mot. Inboard Horiz./2X Line Freq
0.40
Route Spectrum
10-Apr-01 08:20:35

OVRALL= .3045 V-DG

0.32 PK = .2922
LOAD = 100.0
RPM = 3579.
RPS = 59.64
2 x Line Freq. Reference Env/Prf-Std
PK Velocity in In/Sec

0.24

0.16

7140 RPM
0.08
2x turning speed

0
Freq: 7200.0
6800 7000 7200 7400 7600
Ordr: 2.012
Frequency in CPM Spec: .283

The 2 x Line Frequency must be separated from 2 x turning speed

to determine rotor or stator problems. The data collector must be set
The
to a 2sufficient
x Line F number of lines of resolution to separate these two frequencies

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 Vibration analysis can be used to determine rotor problems in motors.
The rotor bar pass frequency has penetrated the narrow band alarm.

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 Vibration Analysis Services

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