Lecture 12 – Vibration

Monitoring and Machine Failure

Lecture 12 – Vibration Monitoring and Machine Failure 1

 New Plan
Predictive
Maintenance
Organisation
Financial Organisational
Implications Change

Structure or Loads
Machine Design Monitoring
Maintenance
FMEA
Techniques
Design
Concepts
Damage
Consequences Identification
Hierarchy

Lecture 12 – Vibration Monitoring and Machine Failure 2

 Lecture Overview
SHM/CM/SPC
Comparison

Data-Driven Model-Driven
Approach Approach

Vibration Data to
Monitoring for Decision
Machine
Damage Sensor Feature
Issues Extraction

Signal Pattern
Processing Processing

Lecture 12 – Vibration Monitoring and Machine Failure 3

 Lecture Overview
„ Vibration Monitoring
„ Vibration Profiles
„ Measuring Vibration
„ Vibration Sources
„ Rotating Machinery
„ Reciprocating/Linear Machinery

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 Machines

Drivers

Intermediate
Drives

Driven
Components

Lecture 12 – Vibration Monitoring and Machine Failure 5

 Vibration Monitoring
„ All mechanical equipment in motion generates a
vibration profile, or signature, that reflects its
operating condition.
„ The above statement is true regardless of speed
or whether mode of operation is rotation,
reciprocation or linear motion.
„ Use of vibration analysis not restricted to
predictive maintenance – can be used to
evaluate fluid flow through pipes and vessels,
detect leaks and improve plant reliability and
performance.

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Introduction to Vibration Monitoring

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 Vibration Profiles
„ Vibration data recorded from machines is
usually extremely complex as there are many
sources of vibration. Each source generates its
own profile which will essentially be added
together to give the composite profile.
„ Time-domain plots must be used for linear and
reciprocating machinery – useful in overall
analysis of machine trains to study operating
condition changes but time-domain data are
difficult to use.

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 Vibration Profiles
„ Time-domain data may be broken down into
their frequency components using a Fast Fourier
Transform (FFT).
„ Frequency-domain data required for equipment
operating at more than one running speed and
all rotating applications.
„ Key to using vibration signature analysis for
predictive maintenance is ability to differentiate
between normal and abnormal vibration profiles.

Lecture 12 – Vibration Monitoring and Machine Failure 9

 Vibration Profiles
„ Many vibrations are normal for rotating or
moving machinery, e.g. normal rotation of shafts
and other rotors, contact with bearings, gear-
mesh etc.
„ Specific problems with machinery generate
abnormal, yet identifiable, vibrations, e.g. loose
bolts, misaligned shafts, worn bearings, leaks
and incipient metal fatigue.

Lecture 12 – Vibration Monitoring and Machine Failure 10

 Vibration Profiles
„ Predictive maintenance using vibration signature
analysis is based on the following:
„ All common machinery problems and failure modes
have distinct vibration frequency components that can
be isolated and identified.
„ Frequency-domain signature is generally used
because it contains discrete peaks, each representing
specific vibration source.
„ There is a cause for each frequency component.
„ When the machine signature is compared over time, it
will repeat until some event changes the vibration
pattern.

Lecture 12 – Vibration Monitoring and Machine Failure 11

 Vibration Monitoring

Lecture 12 – Vibration Monitoring and Machine Failure 12

 Vibration-measuring equipment
„ Vibration data obtained by:
„ Mounting transducers on the machinery at various
locations, typically machine housing and bearing
caps.
„ Using a portable data-gathering device (vibration
monitor or analyser) which can acquire data, FFT and
store.

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Measuring Vibration

Lecture 12 – Vibration Monitoring and Machine Failure 14

Displacement Transducers

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Velocity Transducers

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 Accelerometers

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Monitoring Methods

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 Vibration Sources
„ All machinery with moving parts generates
mechanical forces during normal operation.
„ As mechanical condition of machine changes
because of wear, changes in operating
environment, load variations etc., so do these
forces.
„ Vibration profile that results from motion is the
result of a force imbalance – there is always
some imbalance in real-world applications.

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 Rotating Machinery Vibration
„ A rotating machine has one or more machine
elements that turn with a shaft – e.g. rolling-
element bearings, impellers and other rotors.
„ In a perfectly balanced machine, all rotors run
on their true centreline and forces are equal.
„ In industrial machinery, rotors imbalance will
generally be present due to uneven weight
distribution or due to the imbalance between
generated lift and gravity.

Lecture 12 – Vibration Monitoring and Machine Failure 20

 Rotating Machinery Vibration
„ Pumps, fans, compressors will be subject to
imbalance caused by turbulent or unbalanced
media flow.
„ Combination of these forces with stiffness of
rotor-support system will determine the vibration
level.

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 Reciprocating/Linear Vibration
„ Reciprocating linear-motion machines
incorporate components that move linearly in a
reciprocating fashion to perform work. They are
bidirectional in that the linear movement
reverses.
„ Non-reciprocating linear machines also generate
work in straight line but do not reverse direction.
„ Few machines involve linear reciprocating
motion alone e.g. reciprocating compressor
contains a rotating crankshaft that transmits
power to reciprocating pistons for compression.
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 Reciprocating/Linear Vibration
„ Vibration profiles of reciprocating machines reflect
combination of rotating and linear-motion forces.
„ Frequencies are not always associated with one
complete revolution of shaft e.g. four-cycle engine
requires two crankshaft revolutions to complete a
cycle of all pistons.
„ Level of unbalanced forces substantially higher
than those generated by rotating machines –
spikes in vibration profile due to direction
reversals. (Linear-motion-only machines do not
generate these spikes).
Lecture 12 – Vibration Monitoring and Machine Failure 23
 Next Lecture
„ Vibration Analysis Video
„ Machine Failure Mode Analysis
„ General Failure Modes
„ Failure Modes by Machine-Train Component

Lecture 12 – Vibration Monitoring and Machine Failure 24