BASICS OF VIBRATION MONITORING: A Presentation

MACHINERY REQUIRES ATTENTION TO PERFORM AT DESIRED LEVELS OF PERFORMANCE APPROACH

TOWARDS EQUIPMENT (Fig. 1):

Fig. 1: Normal Approaches towards Equipment

CONDITION MONITORING :

1. A) VIBRATION MONITORING: ON LINE MONITORING and OFF LINE MONITORING

2. B) LUBRICATING OIL MONITORING: OIL PROPERTIES ANALYSIS and WEAR DEBRIS ANALYSIS

ONLINE MONITORING

PERMANENTLY MOUNTED PROBES

ALL ROTARY EQUIPMENT ABOVE 500 KW

BENTLY NEVADA MAKE SYSTEM

SHAFT VIBRTION AS WELL AS CASING VIBRATION

OFFLINE MONITORING

PERIODIC DATA COLLECTION

PORTABLE DATA ANALYZERS ARE USED

ALL ROTARY EQUIPMENT ABOVE 22 KW

CSI MAKE SYSTEM

CONDITION:

PHYSICAL CONDITION:

VIBRATIONS

SOUND

LOOSENESS

INTERNAL CONDITION:

VIBRATION SPECTRUMS

FREQUENCY ANALYSIS

ROTOR POSITION

BEARING METAL TEMPERATURE

OIL CONDITION OIL DEGRADATION, METALS, WEAR PARTICLES IN OIL

Three Stages in Vibration Monitoring:

What to measure from the machine? Identification of parameter and machine

How to measure? Instrumentation requirement

When to measure? Frequency of CM

BASICS OF VIBRATION

What is Vibration (Fig. 2)?

Vibration can be defined as cyclic or an oscillating motion of a component from its mean position.
 Fig. 2: Vibration of Simple Spring Mass System

Units of Measurement:

Displacement : m, mm, microns. mils

Velocity : m/sec, mm/sec , in/sec

Acceleration : m/sec2, g

What causes Vibration?

Unbalance

Misalignment

Bent shaft

Looseness

Eccentricity

Resonance

Anti-friction bearing

Journal bearing

Aerodynamics and hydraulic problem

Electrical problem
 Gear problem

Belt-drives problem

Units of Vibration:

Amplitude: It is the magnitude of vibration signal. How much is it vibrating? Size (severity) of the problem.

Frequency: How many times oscillation is occurring for a given time period? What is vibrating? Source of the
vibration.

Phase Angle: The Phase Angle is the angle (in degrees) the shaft travels from the start of data collection to when the
sensor experiences maximum positive force. How is it vibrating? Cause of the vibration.

Units of Amplitude

Displacement: The distance a structure moves or vibrates from its reference or rest position.

Velocity: Rate of change of displacement. It is the measure of the speed at which the mass is vibrating during its
oscillation.

Acceleration: It is the rate of change of velocity. The greater the rate of change of velocity the greater the forces
(F=ma) on the machines.

When To Use Displacement / Velocity / Acceleration (Fig. 3)?

Fig. 3: When to Use Displacement-Velocity-Acceleration

Systems / Tools for Monitoring

Transducers (Fig. 4): It is a basic device, which converts mechanical motion into electrical signal which can be amplified,
filtered, analysed and displayed to indicate the vibrations and allow diagnosis of the overall machinery health.

Fig. 4: Use of transducers for vibration monitoring

Seismic Sensor

Works on piezo-electrical / moving coil principle

Indirect measurement of shaft vibration.

Directly mounted on machine casing / bearing house.

Absolute vibration in terms of mm/sec or g

The VELOCITY PICK-UP is a contact type transducer.

Within the velocity pick-up, a spring-mass suspension system is used, which is designed to have low frequency. It is a
permanent magnet-mass suspended on a spring and surrounded by a coil attached to the protective housing. A damping fluid
is used to damp the natural frequency Velocity pick-up is limited to low frequency (between 10 Hz and 1500 Hz) for practical
purposes.

Accelerometer (Fig. 5)

The accelerometer consists of a stack of piezoelectric crystals (such as quartz) on which a mass is attached.

When a piezoelectric crystal is stressed, it produces an electric voltage output which is proportion to the stress/force. When
the accelerometer is attached to a vibration body, the crystal is stressed by the inertia of the mass caused due to the
vibration. Electrical voltage output is proportion to the vibration acceleration.

Fig. 5: Several types of transducers.

VIBRATION SIGNALES:

A frequency that is an integral multiple (2, 3, etc.) of a fundamental (1) frequency.

Sub-harmonic. A frequency that is an integral submultiple (1/2, 1/3, etc.) of a fundamental (1) frequency.

Vibration components (on rotating machinery) that are related to shaft speed.

Sub-sychronous. Components of a vibration signal whose frequency is less than 1 shaft speed.
Fig. 6: Dominant frequency vs Nature of Fault

Unidirectional vibrations. i.e. severity is more in radial directions as compared to axial.

Phase difference is 90 in radial directions.

Highly sensible w.r.t. machine rpm. It is directly proportional to machine speed.

FREQUENCY SPECTRUM (Fig. 7)

is a plot of frequency V/s amplitude. The frequency axis may be scaled in direct frequency units Hz or in order of shaft
rotative speed ie. 1X , 2X etc. depending on requirement. Baseline data can also be superimposed on the existing data to
view changes in rotor response from known conditions.
Fig. 7: Sample frequency spectrum plot

BODE PLOT (Fig. 8)

is a transient data plot and display is either 1X or 2X vibration amplitude and phase with respect to shaft rotative speed. This
plot is only available as startup or shutdown data.
This plot is useful in determining the slow roll speed range, balance resonant frequencies, synchronous amplification factor,
heavy spot location and rotor mode shape. Click here to know about causes and effects of piping vibration.

Fig. 8: Sample Bode Plot

Common Causes and Effects of Piping Vibration: A short article

Due to the fact that most of the piping design codes (ASME B 31.3, B31.1, B31.4, B 31.8 etc.) does not address the vibration
issues in a detailed fashion, the damaging effect is normally ignored during design stage and simple static analysis without
attention to vibration is performed on piping systems.

At the same time the vibration tendency of the piping system is increasing to a great extent due to increased flow rates of
process industries through pipes and usage of high strength thin walled piping (flexible) material during design. It is seen that
Vibration causes many problems in operating plants and the problem should be solved during design phase. Major of the
damaging effects of vibration can be mitigated if proper design philosophy is taken while designing the system. This article
highlights the major causes of vibration and their effects in short.

Vibration can be defined as a continuous to and fro motion from an equilibrium position. There are many reasons which can
cause vibration in a piping system. Few major reasons which could cause the vibration are listed below:

There are a variety of excitation mechanism which can be present in a piping system and can produce vibration and finally
failure resulting from fatigue. Few of those causes are listed below:

Flow induced Vibration: Caused by the turbulence of the flowing fluid.

Mechanical forces from Equipment: Caused by the excitation forces of reciprocating and rotary equipments like
pumps, compressors etc.

Pressure Pulsations from reciprocating equipment.

High frequency Acoustic excitations generated by relief valves, control valves or orifice plates.

Water Hammer (Surge) or Momentum changes due to sudden valve closure.

Cavitation or vapour bubble collapse due to localised pressure drop.

Due to sudden flashing of fluid.

Periodic pressure disturbances during a flow past the dead end of branch connection/ instrumental items.

Click here to know basics of vibration monitoring.

Effect of Vibration:
Data has shown that out of all failures and downtimes in any individual plant around 10-15% are because of vibration induced
fatigue. The major effects of vibration are as follows:

Vibration causes dynamic stresses (fatigue) in a piping system. If this stress is more than critical value it will initiate a
crack which will propagate slowly and end in the failure of the item in concern. The more fatigue sensitive places are
the weld point connections where the branch and header is joined together.

In addition to dynamic stresses, vibration results in wearing of surfaces in contact due to cyclical relative motion
between them. This phenomenon is known as Fretting.

Click here to know about considerable points while installing centrifugal pumps at site to reduce vibration.

Considerable points while installing centrifugal pumps at site to reduce

vibration
For proper functioning of the centrifugal pumps in any plant the following points need to be taken care while installing.

Checking the site before installation:

 Make sure the foundation concrete is of sufficient strength.

Only place the pump set on a foundation whose concrete has set firmly.

Only place the pump set on a horizontal and level surface.

Refer to the weights given in the Pump general arrangement (GA) drawing.

All structural work required must have been prepared in accordance with the dimensions stated in the outline
drawing/general arrangement drawing.

Improper installation in potentially explosive atmospheres:

Comply with the applicable local explosion protection regulations.

Observe the information in the data sheet and on the name plates of pump and motor.

Installing the pump assembly:

Always install the pump set in horizontal position to ensure proper self-venting of the pump. Refer Fig. 1:

Fig. 1: Figure showing the foundation of pump

Position the pump on the foundation and use a spirit level to align shaft and discharge nozzle. Permissible deviation:
0.2 mm/m.

If required, use shims (2) to adjust the height. Fit shims between the baseplate/foundation frame and the foundation
itself; always insert them to the left and right of the foundation bolts and in close proximity to these bolts.

For a bolt-to-bolt clearance > 800 mm, insert additional shims halfway between the adjoining holes. All shims must lie
perfectly flush.

Insert the foundation bolts (4) into the holes provided.

 Use concrete to set the foundation bolts (4) into the foundation.

Wait until the concrete has set firmly and then align the baseplate.

Tighten the foundation bolts (4) evenly and firmly.

Grout the baseplate using low-shrinkage concrete with a standard particle size and a water/concrete ratio of 0.5.

Produce flow-ability with the help of a solvent.

For low-noise operation the pump set can be mounted on vibration dampers upon confirmation by the manufacturer.
In this case, only fasten the flexible elements at the baseplate after the piping has been connected.

Expansion joints can be fitted between pump and suction/discharge line.

Observe the permissible forces and moments at the pump nozzles.

Take appropriate measures to compensate thermal expansion of the piping.

The suction lift line/suction head line has been laid with a rising/downward slope towards the pump.

The nominal diameters of the pipelines are at least equal to the nominal diameters of the pump nozzles.

To prevent excessive pressure losses, adapters to larger diameters have a diffuser angle of approximately 8.

Thoroughly clean, flush and blow through all vessels, pipelines and connections (especially of new installations).

Before installing the pump in the piping, remove the flange covers on the suction and discharge nozzles of the pump.

Use a filter with laid-in wire mesh (mesh width 0.5 mm, wire diameter 0.25 mm) of corrosion-resistant material. Use a
filter three times the diameter of the piping. Conical filters have proved suitable.

The volute casing and casing/discharge cover take on the same temperature as the fluid handled.

Make sure the space between the casing cover/discharge cover and the bearing cover is sufficiently vented.

Never close or cover the perforation of the bearing bracket guards.

Never insulate the casing cover and the bearing bracket.

Make sure that the coupling is correctly aligned at all times.

Always check the coupling after the pump has been installed and connected to the piping.

Also check the coupling of pump sets supplied with pump and motor mounted on the same baseplate. Refer Fig. 2.
Fig. 2: Checking the spacer-type coupling with a dial gauge

Mark the installation position of the coupling by dotting marks (balancing condition).

Remove the coupling spacer.

While the pumps coupling is disengaged, also check the direction of rotation.

Check the alignment of the coupling halves with a dial gauge (see Fig. 2). Admissible run-out of coupling face (axial)
maximum 0.1 mm. Admissible radial deviation, measured over the complete circumference, maximum 0.2 mm.

After having installed the pump set and connected the piping, check the coupling alignment and, if required, re-align
the pump set (with the motor). Any differences in shaft centre height between the pump and the motor are
compensated by means of shims.

Check the coupling alignment.

Unscrew the hexagon head bolts at the motor.

Insert shims underneath the motor feet until the difference in shaft centre height has been compensated. Refer Fig.
3.
Fig. 3: Pump Set with Shim

Re-tighten the hexagon head bolts.

Check that the coupling and shaft can easily be rotated by hand.

Always operate the pump set with a coupling guard. If the customer specifically requests not to include a coupling
guard in Vendors delivery, then the operator must supply one! Observe all relevant regulations for selecting a
coupling guard.

Reinstall the coupling guard and step guard, if any.

Check the distance between coupling and coupling guard. The coupling guard must not touch the coupling.

Check the available mains voltage against the data on the motor name plate.

Select an appropriate start-up method.

Change the motors direction of rotation to match that of the pump.

Observe the manufacturers product literature supplied with the motor. Never check the direction of rotation by
starting up the unfilled pump set. Separate the pump from the motor to check the direction of rotation.

Never insert your hands or any other objects into the pump. Check that the inside of the pump is free from any
foreign objects.

The correct direction of rotation of motor and pump is in clock-wise direction (seen from the motor end). If the
direction of rotation is incorrect, check the connection of the motor and the switchgear, if any.

Click here to know about causes and effects of piping vibration

 Click here to know about vibration monitoring methods.