An Introduction to Vibration Analysis

Wajahat Abbas
Manager - Inspection
FFBL Power Company Limited
COURSE SCHEME:
 Course divided in 3 parts
• 1ST PART - FUNDAMENTALS:
◆Vibration definition
◆Why measure vibration
◆Causes of machinery vibration
◆Vibration and machine life
◆Results of machine deterioration
◆Characteristics of vibration
COURSE SCHEME:

• 2ND PART – VIB. TRANSDUCERS:

◆Vibration transducers
◆Accelerometers
◆Vibration frequency analyzers
◆FFT spectral parameters

• 3RD PART- DIAGNOSTICS:

◆Vibration Analysis / diagnostics
VIBRATION DEFINED
◆ Vibration is a periodic, back and forth motion
(oscillation) of an object.

Useful Vibration Harmful vibration

Compressor
Noise
Testing

Destruction

Wear
Ultrasonic
cleaning

Fatigue
MACHINE VIBRATIONS
◆ In industrial plants we are concerned with Machine
Vibrations.
◆Machine Vibration is simply the back and forth
movement of machine or machine components.
WHY MEASURE MACHINE VIBRATION?
◆It is natural for machines to vibrate. Some
vibration is there even in best machines
◆Monitoring machine vibration gives us an
understanding of the “health” of a machine
◆Therefore: vibration level may be normal
◆Mechanical trouble is usually the reason for
excessive vibration: Something causes it!
◆CAUSES: Unbalance, misalignment, worn gears,
looseness………many more!!
WHY MEASURE VIBRATION?
◆ Vibration analysis can
help to detect a wide Imbalance
variety of faults e.g.
Misalignment
◆ Unbalance
◆ Misalignment
◆ Bearing faults
◆ Mechanical looseness
◆ Lubrication problems
Vane wear
Bearing faults
◆ We can detect different Looseness
fault conditions and
Broken rotor bars
correct the problems
as they arise.
CPROBLEMS AVOIDED BY MONITORING
MACHINE VIBRATIONS
◆ Severe Machine Damage
◆ Machine vibration not detected early can lead to severe damage or
requiring costly repair or total machine replacement.
◆ Production Loss
◆ An un-monitored machine is likely to break down and cause production
loss. Regular monitoring helps to ensure that machine is available to
generate money.
◆ Unnecessary Maintenance
◆ Some companies stop machines according to predetermined schedules
to replace parts that are still good and correct problems that do not
exist. By regular monitoring machines are repaired only when required.
◆ Occupational Hazards
◆ Vibrating machines can cause potential safety hazard in case of break
down. Monitoring the machines will avoid such break down.
◆ COST OF FAILING TO MONITOR MACHINE VIBRATION
FAR EXCEEDS THE COST OF IMPLEMENTING A
VIBRATION MONITORING PROGRAM !!
CAUSES OF MACHINERY VIBRATION
◆ Machines vibrate because of internal & external forces.

Machinery Vibration Involves:

◆ Motion of Rotors
◆ Casing Vibrate All
◆ Piping At The
◆ Foundation Same Time
VIBRATION AND MACHINE LIFE
◆ Generates periodic Fatigue Failure
stresses in machine
parts
Wear / Damage
◆ Severe vibration causes
machine parts to come
into contact

◆ Hence Control of vibration is important !

◆ Most common component failure leading to total machine
failure is BEARINGS!
CHARACTERISTICS OF VIBRATION:

Each mechanical problem generates vibration in its own unique

way. It is possible to identify specific nature of the problem by
measuring & noticing its vibration characteristics:

◆ Frequency
◆ Displacement
◆ Amplitude
◆ Velocity
◆ Spike Energy
◆ Acceleration
◆ Phase
WHEN TO USE DISP., VEL. & ACCEL.
VIBRATION FREQUENCY
Definition:
◆ The rate at which a machine component oscillates is called its
Vibration Frequency.
◆ The higher the frequency, the faster the vibration
◆ Like a person’s pulse, vibration frequency is useful indicator
of machine condition.
◆ Frequency = No of Cycles Completed / Second
VIBRATION FREQUENCY
◆ Vibration analyzers provide a direct reading of vibration
frequencies generated by the machines.
◆ Commonly expressed is CPM, Hertz or in terms of Orders.
◆ If a machine operates at 3600 RPM, it is much more
meaningful to know that a vibration occurs at 3600 CPM
(1x RPM) than 60 Hz.
VIBRATION FREQUENCY
SIGNIFICANCE:
◆ Frequency of vibration pinpoints the specific cause of
vibration. Very important analysis / diagnostic tool.
◆ Mostly vibration problems have frequencies directly
related to the rotational speeds.

Fan 2400 RPM If vibration at 2400

CPM, then Fan is
Belt the source of
Motor 3600 RPM vibration
VIBRATION FREQUENCY
SIGNIFICANCE:
◆ Each vibration frequency, related to rotating speed (RPM),
has common causes.
◆ Knowing how frequency of vibration relates to the rotating
speed of the machine components is truly the first step in
the analysis process.
◆ Not all problems will result in vibration frequencies that
are directly related to the rotating speed of the machine
e.g. Antifriction bearing problems.
◆ Different machinery problems cause different frequencies
of vibration
◆ Reduces possible problems from 100s to 10s.
 Frequency
In Terms
Of RPM Most Likely Causes Other Possible Causes & Remarks

1 x RPM Unbalance 1) Eccentric journals, gears or pulleys

2) Misalignment or bent shaft - If high axial vibration
3) Bad Belts - If RPM of belt
4) Resonance
5) Reciprocating forces
6) Electrical problems
7) Looseness
8) Distortion - soft feet or piping strain
2 x RPM Mechanical 1) Misalignment - if high axial vibration
Looseness 2) Reciprocating forces
3) Resonance
4) Bad belts - if 2 x RPM of belt
3 x RPM Misalignment Usually a combination of misalignment and excessive axial
clearances (looseness).
Less than Oil Whirl (less 1) Bad drive belts
1 x RPM than 1/ 2 RPM 2) Background vibration
3) Sub-harmonic resonance
4) "Beat" Vibration
Synchronous Electrical Common electrical problems include broken rotor bars, eccentric
(A.C. Line Problems rotor unbalanced phases in poly-phase systems, unequal
Frequency) air gap.
2 x Synch. Torque Pulses Rare as a problem unless resonance is excited
Frequency
Many Times RPM Bad Gears Gear teeth times RPM of bad gear
(Harmonically Aerodynamic Forces Number of fan blades times RPM
Related Freq.) Hydraulic Forces Number of impeller vanes times RPM
Mechanical Looseness May occur at 2, 3, 4 and sometimes higher harmonics if
severe looseness
Reciprocating Forces
High Frequency Bad Anti-Friction 1) Bearing vibration may be unsteady - amplitude and frequency
(Not Harmonically Bearings 2) Cavitation, recirculation and flow turbulence cause random,
Related) high frequency vibration
3) Improper lubrication of journal bearings
(Friction excited vibration)
4) Rubbing
VIBRATION FREQUENCY
COMPLEX VIBRATION:

◆ Machines can often have several causes of vibration, each

cause having its own unique frequency (i.e. Complex
Vibration).
◆ Each vibration frequency present can be readily identified
along with its cause using standard analysis equipment &
technique.
◆ Knowing the predominant frequency (i.e. with highest
amplitude) is important.
CHARACTERISTICS OF VIBRATION
VIBRATION AMPLITUDE:
◆ Amplitude of vibration is the magnitude of vibration.
◆ A machine with large vibration amplitude experiences large,
fast or forceful vibratory movement.
◆ Magnitude of vibration expressed in terms of signal level.
◆ Displacement
◆ Velocity
◆ Accelerator
◆ Thus vibration amplitude is an indicator of severity of vibration
VIBRATION AMPLITUDE
Displacement:
◆ Total distance traveled by the
vibrating part from one extreme
limit of travel to other extreme
limit.
◆ Severity of vibration depends not
duly on displacement but
frequency as well as FATIGUE
repeated cycles of flexing caused
by excessive vibratory forces.
◆ Complex vibration means
frequencies, higher frequency
vibration with lower displacement
may lead to more fatigue.
VIBRATION AMPLITUDE
Velocity:
◆ Velocity is simply speed measured in a particular direction.
◆ Measure of vibration velocity is a direct measure of fatigue.
◆ Not necessary to know the frequency of vibration in order to evaluate
the severity of vibration velocity since frequency is already a part of
velocity.
◆ A measurement of overall vibration velocity is a valid indicator of the
overall condition of a machine, even for complex vibration.
◆ Industry standard Velocity.
VIBRATION AMPLITUDE
Acceleration:

◆ Rate of change of velocity.

◆ Same problem as with displacement: i.e. necessary to know
the specific frequency of vibration.
VIBRATION AMPLITUDE
Phase:
Definition:
◆ Phase is another name for the relative timing between two
events in different signals.
◆ In machinery application, the phase of equivalent events on
different vibration signals is called relative phase.

Units
◆ Degrees, One complete cycle of vibration equals to 360 Degrees.

o Comparative phase measurements aids in pin pointing the specific

problem associated with a particular frequency.