Typical bearing defects and spectral identification

Below are the most typical bearing defects and their identification in the frequency
spectrum:

 Outer race defects: the spectrum is characterized by the presence of harmonic

peaks of the outer race failing frequency (between 8 and 10 harmonics of the
BPFO).
 Inner race defects: the spectrum shows several harmonic peaks of the inner race
failing frequency (usually between 8 and 10 BPFI harmonics) modulated by
sidebands at 1x RPM.
 Ball or roller defects: they are characterized by the presence in the spectrum of
harmonics of the rolling element deterioration frequency (BSF). In most cases, the
harmonic of greater amplitude usually indicates the number of deteriorated balls or
rollers. They are usually accompanied by defects on the races.
 Cage defects: are characterized by the presence in the spectrum of the cage failing
frequency (FTF) and its harmonics. Generally, a defect in the cage is accompanied
by defects in the races and the FTF usually modulates one of these race failure
frequencies leading to sums and/or differences of frequencies.
 Defects of multiple components: it is quite common to find bearings with multiple
deteriorated components, and in such case multiple failing frequencies and their
corresponding harmonics will appear.
 Looseness: we can distinguish the following types:
o Excessive bearing internal clearance. Usually features a spectral signature
characterized by the presence of synchronous vibration (rotating speed
harmonics), sub synchronous vibration (0.5x RPM) and non-synchronous (1.5x
RPM, 2.5xRPM, 3.5x RPM, etc.)These frequencies sometimes can be
modulated by the FTF.
o Looseness between bearing and shaft. Several rotation frequency harmonics
appear and normally the dominant one is the 3x RPM.
o Looseness between bearing and casing. It presents several harmonics of the
rotating frequency, being the peaks at 1x and 4x RPM the ones with higher
amplitudes.
 Bearing misalignment: as already mentioned in the chapter about misalignment,
spectral signatures are characterized by the presence of vibration at various
harmonics of the rotating frequency, with the amplitude being the most significant at
NB x RPM, where NB is the number of rolling elements in the bearing.
 Inadequate lubrication: lubrication problems are characterized by high frequency
vibration (between 1 kHz and 20 kHz), with bands of peaks spaced apart from each
other, due to the excitation of the resonance frequencies of the bearings in these
frequency ranges.
Figure 9.3: Outer race defect

Figure 9.4: Inner race defect

Figure 9.6: Bearing cage defect

 Frequency bands for the analysis of bearing condition

The possibility of splitting the spectrum overall value into multiple frequency bands
allows us to know in advance the areas in which the most typical problems are usually
manifested and help us to identify them even before we can visualize the spectrum in
frequencies and wave in the time. For typical machines where the aim is monitor low and
medium frequency issues (unbalance, misalignment, looseness, etc.) and high
frequency issues (bearings) we recommend to use the frequency bands indicated in the
following table.

Spectral parameter Bandwidth

Imbalance, misalignment, looseness, rub and belt 1.5 to 2.5x

wear. RPM

Misalignment and looseness. 1.5x to 2.5x

RPM

Looseness, misalignment and BSF. 2.5 to 4.5x

RPM

First harmonics of the bearing fault frequencies 4.5 to 20.5x

BPFO, BPFI and BSF. RPM

Higher bearing fault frequencies harmonics and 20.5 to 50x

presence of frequencies related to electrical RPM
issues.

High frequency spectral band, in units of 1 to 20 kHz

acceleration (G's). Alarm parameter in case of
early bearing deterioration stage, presence of
cavitation or lack of lubrication.

Why Lobe Blowers Produce Vibration?

1. The foundation bolts get loose; it may cause vibration in vertical direction.
2. The couplings don’t cooperate well with each other. (for roots blower having
direct coupled drive)

3. The concrete base of the blower or the foundation is damaged.

 4. The connection pipes with blower were not properly aligned and stresses not relieved
using a flexible connection. Vibration in the piping is transmitted to the blower
5. Bad quality of timing gears.
6. Damaged bearings.
7. Dynamic Balancing of the lobes was not done accurately.
8. Soft foot while installing the blower.
9. V belt alignment or tension incorrectly maintained where blowers are belt driven.

Unbalance: Overhung machines

Spectrum: High 1X in the radial directions but highest in the axial direction.
Waveform: The waveform will be very sinusoidal when viewed in units of velocity.
Phase: Look for 90° phase shift between vertical and horizontal

Soft Foot
The term soft foot is used to describe machine frame distortion. It can be caused by a
condition where the foot of a motor, pump or other component is not flat, square and
tight to its mounting, or many other things, such as machining errors, bent or twisted feet
and non-flat mounting surfaces. Soft foot increases vibration and puts undue stress on
bearings, seals and couplings. Soft foot on a motor distorts the stator housing creating a
non-uniform rotor to stator air gap resulting in vibration at two times line frequency.

Phase can be used to identify soft foot while the machine is in operation. Measure
vertical phase between the foot and its mounting surface. If the joint is tight, the phase
angle is the same between surfaces. If the phase angle is different by more than 20
degrees, the foot is loose or the machine frame is cracked or flimsy.