VA Example Technical Report

Vibration Analysis Report
AN Other Company Limited, Example Report:

25th October 2011.
Report Content(s):
Run Up/Coast Down Analysis on Calorifier Pumps
Details of Engineer, Site Representative and Report Author
Report Prepared By
Tony Riseley
Dynaseq Monitoring Group

Greenfield Business Centre
Greenfield, HOLYWELL
Flintshire. North Wales.
Phone +44 (0) 1352 710600

Fax
+44 (0) 1352 710703
Email sales@dynaseq.co.uk
Web www.dynaseq.co.uk
Date of Survey(s):
25th October 2011.
Our Reference Number:
ANCL11-08.
Dynaseq Monitoring Group Greenfield Business Centre Greenfield Holywell Flintshire North Wales CH8 7GR
TEL: 01352 710600 FAX: 01352 710703 Email: sales@dynaseq.co.uk Web: www.dynaseq.co.uk
Table of Contents
PART ONE: The Report Section
Introduction
Page 3
Site details, diagrams and additional notes.

Run Up / Coast Down Analysis on Sensitising Calorifier Pumps
Page 6
Site details, diagrams and additional notes.
PART TWO: Discussion

Conclusions
Page 10
Advice and recommendations

Further Remarks
Page 11
Basic concepts of vibration analysis and other details
2
1
Part
Report Section
Introduction; Machine Listings; Site Details and Relevant Data
Introduction
Preface
A real-time run up/coast down analysis was requested by AN Other Company to investigate the vibration
levels occurring on the Sensitising P1023A and P1023B 82C Calorifier Pumps since installing a variable
speed drive (VSD) inverter on the installations.
The purpose of this survey was to determine if there were any significant increases in vibration amplitude
when operating at certain speeds, where an offset motor misalignment has been identified on regular
occasions during the routine condition monitoring inspections.
Machine Listings
The following machinery located within the Sensitising Plant at AN Other Company has been monitored during
the course of the survey as follows:(a) Ten individual horizontally mounted belt driven 2.1b (Upper Plant Room) Sensitising Box Section
Fans, each of approximately 2920 RPM, 15 kW capacity and labelled consecutively from No. 1 through to
No. 10 and identified as follows: (i) K1102; (ii) K1107; (iii) K1103; (iv) K1108; (v) K1104; (vi) K1109; (vii)
K1105; (viii) K1110; (ix) K1106 and (x) K1111.
(b) One single horizontally mounted 2.1b (Upper Plant Room) Sensitising Extraction Fan, identified as:
K1118, of 960 RPM, 11.0 kW capacity.
(c) Two individual horizontally mounted belt driven 2.1a Sensitising (Lower Plant Room) Main Conditioner
Fans as follows: (i) Main Conditioner Fan No. 1 K1101 of 1460 RPM, 25 Hp capacity and (ii) Auxiliary
Conditioner Fan No. 1 K1117 of 1460 RPM, 22.0 kW capacity.
(d) Two identical horizontally mounted variable-speed, direct-coupled 2.1 a Sensitising (Lower Plant Room)
82 C Calorifier Pumps, identified as: P1023A and P1023B, each of 2950 RPM, 40 Hp capacity.
3
Data Collection
The machines were monitored using an SKF DC460 dual channel digital FFT analyser which is a combined
portable data collector and sophisticated signal analyser, capable of detecting the following fault types:
bearing damage
lubrication problems
imbalance
positional misalignment
angular misalignment
loading anomalies
looseness
gearbox component wear/damage
conveyor belt tracking
resonance and structural related problems
foundation movement
coupling damage
excessive stress points
inadequate support
application problems
hysteresis whirl
faulty belt drives
The analysis conducted on site highlights any of the above fault types and on detection will be documented in
this report, stating the exact defect, cause and severity.
4
Spectrum Analysis: Description and Purpose

Before presenting this report in further detail, it may be necessary to explain some of the terminology used
when referring to the recorded spectra:
Velocity Spectrum
Velocity is movement expressed in terms of time and in our case, measured in mm/sec.. The ISO10816-3
vibration severity standard categorises certain types of machinery (in accordance with capacity; rotational
speed and operating circumstances) into certain zones such as: Excellent; Acceptable; Unsatisfactory
and Unacceptable.
Acceleration Spectrum
Acceleration is the rate of change of velocity (in other words, movement per second per second) and is
measured in G. Acceleration is a high frequency spectral signal relating to typical faults such as: bearing
fatigue; gear wear; complex or multiple component damage; excessive loading anomalies and aerodynamic
related problems on rotors or impellers.
Enveloped Spectrum
Enveloping is the relatively new technique, which filters and processes the normal high frequency
characteristics naturally produced by the combined components of a bearing. In the past, conventional
techniques only permitted the analysis of the overall signal, which could actually indicate an array of anomalies
other than a bearing defect. This method became an increasingly unreliable and misleading technique,
especially when levels began to rise - for example, it was impossible to distinguish between a genuine bearing
defect and a typical loading related problem.
When utilising the enveloping technique, the following processes take place:
The complex signal is demodulated by use of a band pass filter centred on the resonant carrier waveform.
The entire process is enveloped (half wave rectified). The individual components of a bearing such as faulty
inner/outer races; cages and rollers/balls are now detectable at specific frequencies.
The technique is particularly useful on slow running machinery (e.g., below 10 RPM) where conventional
methods fail to produce any relevant signals to analyse.
The investigation can now be classified into the following areas:
1. Site Details.
2. Vibration Measurements on the machines.
5
Run Up / Coast Down Analysis on Calorifier Pumps

Inspection of the Supporting Structure and Operating System
The Calorifier Pumps selected for monitoring appeared to be adequately placed upon suitable foundations and
supporting structures. Hence, the survey was primarily concerned with the vibration levels obtained from the
machine itself as opposed to foundations and structural related problems.
Run Up / Coast Down Analysis

During this particular test, the 2.1a Sensitising Plant 82C Calorifier Pumps P1023A and P1023B were allowed
to operate from standstill to full rotational speed (run up analysis) and from full speed down to standstill (coast
down analysis). The purpose of these tests was to highlight any shaft critical frequencies, random impacts
and/or other anomalies that can easily be missed using stationary signal analysis alone.
Data was collected in real-time at each of the following monitoring positions: (i) motor non drive end
(horizontal) and (ii) motor drive end (horizontal). It has long been suspected that these pumps have been
operating close to a shaft critical frequency since installing a pressure sensitive variable speed drive on each
installation, whereby an offset misalignment of the motor has been observed during the routine condition
monitoring surveys at approximately 81 - 85 % operating speed.
Figure 1: Photograph identifying the dual channel sensor locations on the

non drive end and drive end positions of the 2.1a Sensitising Plant 82C
Calorifier Pump motor, using magnetic mounted accelerometers connected
to an SKF DC460 analyser.
The following results were obtained during the coast up analysis at 2x rotational frequency from the motor non
drive end and motor drive end bearings, all within the horizontal plane:-
6
Coast Up/Down Analysis Results on 2.1a Sensitising 82C Calorifier Pumps P1023A and P1023B
Freq.
Pump P1023A
Pump P1023B
Notes and observations
mtr-nde
mtr-de
mtr-nde
mtr-de
Hz
mm/s
mm/s
mm/s
mm/s
73.4
2.73
2.63
1.36
2.49
Both motors operating normally
75
2.86
1.45
2.59
76.6
3.32
3.05
1.60
2.52
78.1
4.49
4.24
2.01
3.04
First observation of significant 2x rpm vibration on P1023A motor
79.7
7.12
6.71
2.42
3.75
P1023A motor now operating above ISO 10816-3 Unusable Zone
81.3
9.39
8.63
3.42
5.27
First observation of significant 2x rpm vibration on P1023B motor
82.8
7.32
6.66
4.86
7.51
Both P1023A & P023B operating above the ISO 10816-3 Unusable
84.4
4.99
4.65
6.61
10.2
Decreasing amplitudes on P1023A & increasing amplitudes on P1023B
85.9
4.36
7.15
10.9
P1023A Satisfactory Zone / P1023B Unusable Zone
87.5
3.57
3.12
6.19
9.32
P1023B continuing to operate in the ISO 10816-3 Unusable Zone
89.1
2.61
2.46
5.15
7.6
P1023B continuing to operate in the ISO 10816-3 Unusable Zone
90.6
2.61
2.36
4.22
6.1
P1023B operating in the ISO 10816-3 Unsatisfactory Zone
92.2
2.52
2.15
3.48
4.92
P1023B operating in the ISO 10816-3 Unsatisfactory Zone
93.8
2.17
1.79
2.87
3.95
Both motors operating normally
95.3
1.78
1.42
2.63
3.45
96.9
1.64
1.33
2.43
3.21
98.4
1.40
1.19
2.18
2.83
Table 1: Table 1 identifying potential shaft critical frequencies (measured in Hz) and velocity amplitudes (measured in mm/sec. RMS) during the
run up / coast down analysis conducted on the motor non drive end and motor drive end monitoring positions of the Sensitising 2.1a 82C
Calorifier Pumps P1023A and P1023B. The dark green, light green, yellow and red boxes correspond with the ISO Vibration Severity Standard:
10816-3 Group 3 (15 kW 300 kW pump with external driver rigid mount) ratings of: Excellent, Satisfactory, Unsatisfactory and Unusable
consecutively.
As observed in the table above, there is a potential shaft critical zone between the operating speed of 2351 2490 rpm (79.7% - 84.4% running speed) occurring on Pump P1023A and 2399 - 2720 rpm (81.3% - 92.2%
running speed) occurring on Pump P1023B, culminating in the highest velocity amplitude of 10.9 mm/sec. at
85.9 Hz (2x rotational frequency) on the motor drive end bearing of Pump P1023B. The prolonged use of
these motors operating in this speed range should be avoided if possible.
The following pages contain the coast up spectral analysis obtained from each motor and clearly illustrate the
problem area.
7
P1023A 82 C Calorifier Pump Run Up Analysis
Figure 2: Run Up Analysis conducted on the motor non drive end bearing of 2.1a Calorifier Pump P1023A showing significant emergence of 2x rpm
vibration (misalignment) at 81.3 Hz (corresponding to 81.3% operating speed) over a 131 second sample (32768 samples/21 spectra/40KHz spacing).
Figure 3: Run Up Analysis conducted on the motor drive end bearing of 2.1a Calorifier Pump P1023A showing significant emergence of 2x rpm vibration
(misalignment) at 81.3 Hz (corresponding to 81.3% operating speed) over a 131 second sample (32768 samples/21 spectra/40KHz spacing).
8
P1023B 82 C Calorifier Pump Run Up Analysis
Figure 4: Run Up Analysis conducted on the motor non drive end bearing of 2.1a Calorifier Pump P1023B showing significant emergence of 2x rpm
vibration (misalignment) at 85.9 Hz (corresponding to 85.9% operating speed) over a 131 second sample (32768 samples/21 spectra/40KHz spacing).
Figure 5: Run Up Analysis conducted on the motor drive end bearing of 2.1a Calorifier Pump P1023B showing significant emergence of 2x rpm vibration
(misalignment) at 85.9 Hz (corresponding to 85.9% operating speed) over a 131 second sample (32768 samples/21 spectra/40KHz spacing).
9
2
Part
Discussion
Advice and Recommendations
1
Recommendations for 2.1a 82 C Calorifier Pumps P1023A & P1023B
2.1a Sensitising 82 C Calorifier Pumps P1023A & P1023B - URGENT PRIORITY (operating at
shaft critical frequency)
The Sensitising 82 C Calorifier Pumps P1023A and P1023B proved to be operating above the
Unacceptable Zone as specified by the Vibration Severity Standard: ISO10816-3.
The Coast Up/Coast Down Analysis clearly highlighted a potential shaft critical zone between the operating
speed of 2351 - 2490 rpm (79.7% - 84.4% running speed) occurring on Pump P1023A and 2399 - 2720 rpm
(81.3% - 92.2% running speed) occurring on Pump P1023B, culminating in the highest velocity amplitude of
10.9 mm/sec. at 85.9 Hz (2x rotational frequency) on the motor drive end bearing of Pump P1023B (should be
less than 4.5 mm/sec.).
The prolonged use of operating these motors in this speed range should be avoided if possible; there is a
potential risk of the internal rotor catching the stator or secondary induced mechanical damage may be caused
to the coupling or bearings.
There are three solutions to overcome this problem:1. Operate the pumps at 100% speed only (the motors in use are not dynamically balanced to run at any
other speed).
2. Operate the pumps outside the shaft critical speed zone in each case (highlighted above).
3. Replace BOTH motors and fit a variable speed rated motor to each installation.
If there is any aspect of this report you wish to discuss in greater detail, or any further points you would like to raise yourself, then
please do not hesitate to contact Tony Riseley on Tel. 01352 710600 or Email sales@dynaseq.co.uk.
10
Further Remarks
Basic Concepts of Vibration Analysis
What is Vibration?
Introduction
Vibration is the disturbance from equilibrium, which propagates in time from one place to another and exists in
all rotating and reciprocating machinery. An ideal machine would produce no vibration at all because all
energy would be channelled into the machine function. A good design will produce low levels of inherent
vibration, however, as the machine wears, foundations settle and parts deform, subtle changes in the dynamic
properties of the machine begin to occur. Shafts become misaligned, parts begin to wear, rotors become
unbalanced and tolerances increase. All of these factors are reflected in an increase in vibration energy, which
dissipates throughout the machine, excites resonance and puts considerable strain on bearings. Cause and
effect reinforce each other and the machine progresses towards ultimate breakdown.
A machine may contain many complex vibrations, made up of a wide-range of superimposed sinusoidal and
random components. This multi-complex signal can be broken down into its constituent frequency
components by using F.F.T. analysis (Fast Fourier Transform) commonly referred to as a Spectrum. The
following table highlights the many common faults and their characteristic frequencies in terms of rotation
speeds:
Nature of Fault
Frequency of Dominant
Vibration (Hz=rpm/60)
Rotating members out of

balance
1 x rpm
Misalignment & Bent Shafts
Usually 1 x rpm; Often 2 x

rpm and sometimes 3 or 4 x
rpm
Direction
Remarks
Radial
A common cause of excess vibration

in machinery.
Radial & Axial
A common fault.
Uneven vibration levels, often with
shocks. Impact Rates f (Hz)
Damaged rolling element

bearings (ball, roller etc.)
Impact rates
individual
component
for the
bearing
Also vibrations at high

frequencies (2 to 60 KHz)
often related to radial
resonance in bearings
Outer Race defect: f(Hz) = n/2 x fr (1BD/PD x Cos )

Radial and Axial
Inner Race defect: f(Hz) = n/2 x fr (1+

BD/PD x Cos )
Ball defect: f(Hz) = PD/BD x fr [12
(BD/PD x Cos ) ]
N = number of balls or rollers
fr = relative rev./s between races
11
Journal bearings loose in

housing
Sub-harmonics of shaft rpm,

exactly or 1/3 x rpm
Primarily Radial
Looseness may only develop at

operating speed and temperature
(e.g. turbo machines).
Oil film whirl or whip in

journal bearings
Slightly less than half shaft

speed (42% to 48%)
Primarily Radial
Applicable to high speed (e.g. turbo)

machines.
Primarily Radial
Vibrations excited when passing

through critical shaft speed are
maintained at higher shaft speeds.
Can sometimes be cured by
checking
tightness
of
rotor
components.
Radial and Axial
Sidebands around tooth meshing

frequencies indicate modulation (e.g.
eccentricity)
at
frequency
corresponding to sideband spacings.
Normally only detectable with very
narrow-band analysis and cepstrum.
Hysteresis Whirl
Shaft critical speed
Damaged or worn gears
Tooth meshing frequencies

(shaft rpm x number of
teeth) and harmonics
Mechanical looseness
2 x rpm
Faulty belt drive
1,2,3 & 4 x rpm of belt
Radial
Unbalanced reciprocating
forces and couplings
1 x rpm and/or multiples for

higher order imbalance
Primarily Radial
Increased turbulence
Blade and vane passing

frequencies and harmonics
Radial and Axial
Increasing levels indicate increasing

turbulence.
Electrically
vibrations
1 x rpm or 1 or 2 times
synchronous frequency
Radial and Axial
Should disappear when turning off

the power.
induced
Also sub and inter-harmonics, as for

loose journal bearings.
The precise problem can be usually
identified visually with the help of a
stroboscope.
Figure 6: Table identifying common machinery faults and characteristic frequencies in terms of rotational speed.
12
Evaluation of Rotating Machine Condition using ISO10816-3 Vibration Severity Standard

The ISO Committee have completely revised the old ISO2372 Vibration Severity Standard for evaluating insitu performance of rotating machines. The new standard: ISO10816-3 accommodates the many changes that
have taken place in the design and operating frequencies of modern process machinery.
The vibration criteria in this standard applies to the machine sets, with for example steam turbine or electric
drives, having a capacity above 15 kW and operating between speeds of 120 RPM and 15000 RPM. Machine
sets covered by this standard include: (i) Steam Turbines with a capacity up to 50 MW; (ii) Steam turbine sets
with a capacity greater than 50 MW and speeds below 1500 RPM; (iii) Rotary Compressors; (iv) Industrial gas
turbines up to 3.0 MW capacity; (v) Pumps of centrifugal, mixed or axial flow type; (vi) Electrical motors of any
type and (vii) Blowers or fans, not of lightweight sheet metal construction.
Classification according to Machine Type and Application
Significant differences in the design; type or bearings and support structures requires a separation into
different groups. Machines in these groups may have horizontal, vertical or inclined shafts and can be
mounted on rigid or flexible supports.
Group 1: Large machines rated above 300 kW; electrical machines with a shaft height H 315 mm.
Group 2: Medium machines with a rated power above 15 kW up to and including 300 kW: electric machines with a
shaft height 160 mm H 315 mm.
Group 3: Pumps with multi vane impeller and separate driver, rated above 15 kW capacity.
Group 4: Pumps with multi vane impeller and integrated driver, rated above 15 kW capacity.
ISO10816-3 Vibration Severity Standard
rigid
flexible
Pumps > 15 kW radial, axial, mixed flow
rigid
flexible
rigid
flexible
Medium sized
machines 15 kW <
P 300 kW
Large machines 300

kW < P < 50 MW
0.44
7.1
0.28
4.5
0.18
3.5
0.11
2.8
0.07
2.3
0.04
1.4
0.03
0.71
0.02
mm/sec.
inch/s
Velocity
flexible
RMS
11
10 - 1000 Hz r > 600 rpm

2 - 1000 Hz r > 120 rpm
rigid
RMS
FOUNDATION
MACHINE TYPE
Integrated driver
External driver
Motors 160 mm
H < 315 mm
Motors 315 mm
H
Group 4
Group 3
Group 2
Group 1
GROUP CLASSIFICATION
Figure 7: Table identifying ISO10816-3 Vibration Severity Standard.
13
Human exposure to vibration within buildings

Structural vibration in buildings can be detected by the occupants and can affect them in many ways: their
quality of life can be reduced as also their working efficiency. Building vibrations as they affect people may be
classified as impulsive or continuous as follows:
(a) Impulsive vibration is a rapid build-up to a peak followed by a damped decay which may or may not
involve several cycles of vibration. It can also consist of a sudden application of several cycles at
approximately the same amplitude, providing that duration is short, i.e. less than 2 seconds.
(b) Continuous vibration is vibration which continues uninterrupted for either a day time period of 16 hours or
a night time period of 8 hours, for example 23-00 to 07-00.
When measuring vibration in these circumstances, data is normally acquired on a building structural surface
supporting a human body. In some cases, measurements may have to be taken outside the structure, or on
some other surface other than the point of entry to the human subject.
The evaluation of human exposure to vibration in buildings standard: BS 6472 defines the factors which
influence human response to repeated and prolonged vibration exposure.
Economic benefits of an effective Vibration Monitoring program

When implemented correctly, vibration monitoring will bring about the following:
Increase in the average time between overhauls.
Increased productivity and reduced maintenance costs.
Virtual elimination of unexpected breakdowns.
Increased reliability.
Elimination of secondary damage.
Elimination of component waste (no replacement or serviceable components).
Reduction of spares and stock.
Reduction in business interruption and damage insurance premiums.
Reduced repair duration.
Improved product quality.
Downtime may be scheduled.
14

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Vibration Analysis Report

AN Other Company Limited, Example Report:

Details of Engineer, Site Representative and Report Author

Dynaseq Monitoring Group

Phone +44 (0) 1352 710600

Site details, diagrams and additional notes.

Site details, diagrams and additional notes.

PART TWO: Discussion

Advice and recommendations

Basic concepts of vibration analysis and other details

Spectrum Analysis: Description and Purpose

Run Up / Coast Down Analysis on Calorifier Pumps

Run Up / Coast Down Analysis

Figure 1: Photograph identifying the dual channel sensor locations on the

Both motors operating normally

First observation of significant 2x rpm vibration on P1023A motor

P1023A motor now operating above ISO 10816-3 Unusable Zone

First observation of significant 2x rpm vibration on P1023B motor

Decreasing amplitudes on P1023A & increasing amplitudes on P1023B

P1023A Satisfactory Zone / P1023B Unusable Zone

P1023B continuing to operate in the ISO 10816-3 Unusable Zone

P1023B continuing to operate in the ISO 10816-3 Unusable Zone

P1023B operating in the ISO 10816-3 Unsatisfactory Zone

P1023B operating in the ISO 10816-3 Unsatisfactory Zone

Both motors operating normally

P1023A 82 C Calorifier Pump Run Up Analysis

P1023B 82 C Calorifier Pump Run Up Analysis

Recommendations for 2.1a 82 C Calorifier Pumps P1023A & P1023B

Rotating members out of

Misalignment & Bent Shafts

Usually 1 x rpm; Often 2 x

A common cause of excess vibration

Radial & Axial

Damaged rolling element

Also vibrations at high

Outer Race defect: f(Hz) = n/2 x fr (1BD/PD x Cos )

Inner Race defect: f(Hz) = n/2 x fr (1+

Journal bearings loose in

Sub-harmonics of shaft rpm,

Looseness may only develop at

Oil film whirl or whip in

Slightly less than half shaft

Applicable to high speed (e.g. turbo)

Vibrations excited when passing

Radial and Axial

Sidebands around tooth meshing

Shaft critical speed

Damaged or worn gears

Tooth meshing frequencies

Faulty belt drive

1,2,3 & 4 x rpm of belt

1 x rpm and/or multiples for

Blade and vane passing

Radial and Axial

Increasing levels indicate increasing

Radial and Axial

Should disappear when turning off

Also sub and inter-harmonics, as for

Evaluation of Rotating Machine Condition using ISO10816-3 Vibration Severity Standard

ISO10816-3 Vibration Severity Standard

Pumps > 15 kW radial, axial, mixed flow

Large machines 300

10 - 1000 Hz r > 600 rpm

Figure 7: Table identifying ISO10816-3 Vibration Severity Standard.