APPLICATION DATA

T R O L E X L I M I T E D , N e w b y R o a d , H a z e l G r o v e , S t o c k p o r t , C h e s h i r e S K 7 5 D Y, U K . Tel: +44 (0)161-483 1435 Fax: +44 (0)161-483 5556 E-mail: sales@trolex.com Internet: www.trolex.com
Issue B. 10/02

CONTENTS
PAGE

INTRODUCTION

1. WHAT

IS VIBRATION?

2. HOW

CAN VIBRATION BE USED TO EVALUATE MACHINE CONDITION?

3. TYPES

OF VIBRATION MONITORING.

13

4. HOW

TO SELECT AND USE THE CORRECT VIBRATION EQUIPMENT.

17

5. TYPICAL

APPLICATIONS FOR

TROLEX

VIBRATION MONITORING EQUIPMENT.

33

APPENDIX A

UNDERSTANDING

AND

UTILISING

THE

VIBRATION

INFORMATION OBTAINED.

41

INTRODUCTION
This application note is intended to give the reader a basic grounding in the causes and effects of vibration, along with methods for utilising the information obtained from measuring vibration to diagnose machine health. It will further discuss the merits of the various methods of monitoring vibration and explain how these can be optimised to provide the best results. Finally, the application notes will give some examples of how vibration monitoring can be implemented.

1. W H AT

I S V I B R AT I O N ?
Vibration is the response of a system to an internal or external stimulus causing it to oscillate or pulsate. While it is commonly thought that vibration itself damages machines and structures, it does not. Instead, the damage is done by dynamic stress, which causes fatigue of the materials; and the dynamic stresses are induced by vibration. Amplitude of vibration is also dependent on the dynamic resistance of a system. For example, if a machine is placed on rubber mounts, the amplitude of vibration is likely to increase due to less dynamic resistance for the same imposed dynamic forces. The transmission of vibration to the floor and surrounding structures will be less, but the vibration within the machine will likely increase. However, no additional damage will be done to the machine since the same forces (and therefore, fatigue stresses) will remain the same within this machine (as compared to when the machine was directly mounted to the floor).

Vibration has three important parameters which can be measured: 1. Frequency How many times does the machine or structure vibrate per minute or per second? 2. Amplitude How much vibration in microns, mm/sec or g's? 3. Phase How is the member vibrating in relation to a reference point?

1.1

What is vibration frequency and how does it relate to a time waveform?

The figure below shows how the frequency can be calculated from the displacement waveform, by measuring the time period (T) of one cycle and inverting to determine the frequency Hz. This is an example of a time waveform which plots Vibration Amplitude versus Time. This waveform is a truly sinusoidal waveform from which direct comparisons can be made between its Peak-to-Peak, Peak and RMS amplitudes (see section 1.5). Frequency is expressed in Hertz (where 1 Hertz or Hz = 1 cycle per second).
Figure 1
Frequency = 1/Period = 1 T

DISPLACEMENT

UPPER LIMIT TIME

NEUTRAL POSITION

LOWER LIMIT
Period (T) (1 complete cycle)

Time waveforms are an excellent analytical tool to use when analysing gearboxes. The sensor can be attached close to the input or the output shaft bearing to check for broken or chipped gear teeth. The following is a typical example of how a display for one broken tooth would appear as a time waveform, shown in Figure 2.
Figure 2

+
AMPLITUDE

ONE IMPACT EVERY REVOLUTION FROM THE BROKEN TOOTH

TIME (sec.)
1 Rev. 1 Rev. 1 Rev.

Here is how it would typically be displayed in the frequency domain:

AMPLITUDE
1 x RPM

FREQUENCY

Note, however, that imbalance, misalignment, bent shaft, eccentric rotor, and other problems also often produce a similar display in the frequency domain. Time waveforms are particularly useful for low-speed shafts and gears, even if some never rotate a full revolution (basically just rocking back and forth). In this case, time waveforms are virtually the only analytical tool which can be effectively used.

1.2

What is vibration amplitude?

Vibration amplitude can be expressed in terms of displacement, velocity or acceleration.

1.2.1

What is Vibration Displacement? Displacement is a measure of the total travel of the mass back and forth. Displacement is usually expressed in microns (where 1 micron, = .001 millimetre). When a machine is being subjected to excessive dynamic stress at very low frequencies, displacement may be a good indicator of vibration severity since the machine (or structure) may be flexing too much, subjected to impacts, or simply being bent too far.

1.2.2

What is Vibration Velocity? The velocity of the vibration is a measure of the speed at which the mass is moving or vibrating during its oscillations. The faster a machine flexes, the sooner it will fail in fatigue. Vibration velocity is directly related to fatigue. Note from the example of the oscillating mass suspended from a spring in Figure 3, that velocity reaches its maximum value (or peak) at the neutral position where the mass is fully accelerated (acceleration is zero) and now begins to decelerate as shown in Figure 3. Velocity is expressed as millimetres per second (mm/sec).
Minimum Velocity

DISPLACEMENT

Figure 3
VELOCITY FROM THE DISPLACEMENT CURVE.

UPPER LIMIT TIME

Maximum Velocity

NEUTRAL POSITION

LOWER LIMIT
Minimum Velocity

However, if an analyser were used to directly measure peak velocity, it would select the highest peak or excursion that the velocity time waveform would make. From an oscilloscope display, the peak velocity would be the highest peak in the display as shown in Figure 4. In this case, it is 0.7 mm/sec because it is the highest peak, position or negative.
+
VELOCITY
0.2 0.4 0.3 0.4

Figure 4
HOW TO DETERMINE PEAK VELOCITY FROM AN OSCILLOSCOPE DISPLAY.

0
0.2 0.3

0.7

0.5

1.2.3

What is Vibration Acceleration? When a machine housing vibrates, it experiences acceleration since it continually changes speed as it oscillates back and forth. Acceleration is greatest at the instant at which velocity is at its minimum. That is, this is the point where the mass has decelerated to a stop and is about to begin accelerating (moving faster) again in the opposite direction. Acceleration is the rate of change in velocity and is normally measured in units of g's (where 1g = 9.81ms2). The greater the rate of change of velocity, the greater will be the forces (and stresses) on this machine due to the higher rate of acceleration. At high frequencies, failure of a machine may result from excessive forces which break down the lubrication allowing the surface of bearings to fail (due to metal-to-metal contact). These excessive forces are directly proportional to acceleration (Force = mass x acceleration). Acceleration is probably the most difficult measure of vibration amplitude to grasp, but this is the parameter most often directly measured in the field with the use of an accelerometer. Thus, it is important to gain a good understanding of it.

1.3

What is vibration phase?

Phase is a measure of how one part is moving (vibrating) in relation to another part, or to a fixed reference point. Phase is mostly used as an analytical tool, when initially setting up a machine, to ensure it has been mounted and aligned correctly. It is rarely used for continuous monitoring of machine condition.

1.4

What is a vibration spectrum (also called an "FFT" or "signature")?

This frequency domain presentation of a time waveform is called a "spectrum". This is sometimes referred to as a "vibration signature" or an "FFT" if an FFT analyser is used.

Trolex can provide a range of vibration sensor capable of connection to most industry standard FFT analyser.

1.5

The difference between RMS, peak and peak-to-peak amplitude.

It is possible to convert from one amplitude parameter to another, using either electronic conversion or mathematical formula. However, if a peak reading is taken of one parameter, then the parameter which is being calculated will also be a peak value. The electronics or software, can also convert between rms (root mean square), peak and peak-to-peak. Figure 5 shows the relationship between rms, peak and peak-to-peak, for a purely sinusoidal waveform.
Figure 5
RELATIONSHIP BETWEEN rms, PEAK AND PEAKPEAK ON A PURELY SINUSOIDAL WAVEFORM. SINUSOIDAL MOTION UPPER LIMIT NEUTRAL POSITION rms LOWER LIMIT AVG PEAK PEAK -TOPEAK

MULTIPLY VALUE OF BY TO OBTAIN

PEAK -TOPEAK

PEAK

rms

AVERAGE

PEAK-TO-PEAK PEAK rms AVERAGE

1.000 .500 .354 .318

2.000 1.000 .707 .636

2.828 1.414 1.000 .900

3.142 1.571 1.5 1.000

However, when the time waveform is not sinusoidal in nature (see figure 6), peak and peak-to-peak readings become less useful and rms is most often used.
Figure 6

AMPLITUDE

TIME

rms amplitude gives a more accurate representation of the energy within the vibration and hence the force that will be exerted by the vibration.

2. H O W

C A N V I B R AT I O N B E U S E D T O E VA L U AT E

MACHINE CONDITION?

The causes of vibration in rotating machinery are numerous. These can originate from machine set-up problems such as: Imbalance of system Mis-alignment of shafts Bent shafts Mechanical looseness Ineffective mounting structures

Alternatively, they can be caused by dynamic problems such as: Bearing deterioration Loose parts Build up on fan blades Chipped blades/rotors Geartooth wear/breakage Loss of lubrication

If these problems are left unattended, some quite catastrophic problems can result. These can vary from downtime, lost whilst a seized bearing is replaced, to a fan that completely disintegrates when the out-of-balance causes blades to impact on the casing.

By utilising vibration monitoring, an early warning of impending failure can be obtained, allowing preventative maintenance to be instigated. Analysis of the vibration by a skilled engineer using frequency analysis can allow the problem to be pinpointed.

2.1

When to use displacement, velocity or acceleration

Displacement is generally thought to be the most useful vibration parameter when vibration frequencies are less than 10Hz. However, to be applicable in analysis of the vibration severity, the displacement must be assessed in conjunction with the frequency (Hz). Figure 7 gives an indication of severity levels with regard to displacement and frequency.

VIBRATION FREQUENCY - Hz
1,000 2,000 3,000 4,000 5,000 100 200 300 400 500

Figure 7
VIBRATION DISPLACEMENT & VELOCITY SEVERITY CHART FOR GENERAL HORIZONTAL ROTATING MACHINERY.
100.0 80.0 60.0

40.0 30.0 20.0

10.0 8.0

VIBRATION DISPLACEMENT MICRONS rms

6.0

4.0 3.0

2.0

1.0 0.8 0.6 0.4 0.3 0.2

100,000

10,000

20,000

30,000

40,000

50,000

VE RY RO SL IG H TL Y RO U G
16

RO U G

U G H H

FA IR G O O D G O VE RY SM VE RY SM EL Y SM O EM

.0 m m

H
8. 0

/s ec . m m

0.1 0.08 0.06 0.04 0.03 0.02

0.01

10

VIBRATION VELOCITY - mm/sec - PEAK

EX TR

O D TH
4. 0

O O O O TH O TH

/s ec . m /s ec . m /s ec . 1. 0 m m /s ec . 0. 5 m m /s . ec m m e /s c. m m ec /s . 0. 5 12 2 0. 5 2. 0 m m

Acceleration is most widely used when the vibration frequency is in excess of 1kHz. Again, acceleration needs to be used in conjunction with vibration frequency to analyse the results. Figure 8 gives an indication of severity levels with regard to acceleration and frequency.

Figure 8
VIBRATION ACCELERATION & VELOCITY SEVERITY CHART FOR GENERAL HORIZONTAL ROTATING MACHINERY.
30

1.5

7 5 2 6

10 5

1 .5

.1

.05

E
.01

GH OU YR VER GH ROU GH ROU TLY R H FAI SLIG OD GO OD GO RY VE TH OO SM TH OO SM Y VER OTH MO YS EL EM XTR

.78

.39

.19 .09

8 9

.04

ACCELERATION - G's PEAK

.005

.001 300 400 500 600 700 900 800 1000 2000 3000 4000 5000 6000 7000 8000 9000 10,000

FREQUENCY - Hz

Velocity is the most commonly used vibration signal and is fairly independent of

mm/sec

vibration frequency over the range 10Hz to 1kHz. This is useful for monitoring slowly rotating machines.

Trolex manufactures a range of displacement, velocity and acceleration sensors that are specifically designed for use with the wide range of monitoring and analysis equipment available. These have been optimised for use with the Trolex range of monitoring equipment.

11

VIBRATION VELOCITY - mm/sec pk-pk

6.2

3.1

2.2

How much is too much vibration?

Through the years, the general vibration severity chart (Figure 9) has been used to assess machine condition. However, this was intended to be used as a guide and not an absolute reference. Installation of the equipment and maintenance will have a significant effect on the vibration levels seen. Although the chart can be used as a general indication, trending of the vibration levels with time will give a better indication of the change in condition of the machine. On fixed monitoring equipment, warning and alarm levels can be set to be within the good condition zone.

Figure 9

rms velocity v (mm/s)

CLASS I

CLASS II

CLASS III

CLASS IV

0.28 0.45 0.71 1.12 1.80 2.80 4.50 7.10 11.20 18.00 28.00 45.00

GOOD USA ATT BLE E N T I ON NOT USABLE

CLASS I: Individual parts of engines and machines, integrally connected with the complete machine. CLASS II: Medium or large machines, (typically electrical motors with 15 to 75KW output) CLASS III: Large prime movers and other large machines with rotating masses mounted on rigid and heavy foundations. (300KW output). CLASS IV: Large prime movers and other large machines or turbines with rotating masses mounted on foundations which are relatively soft.

12

3. T Y P E S

O F V I B R AT I O N M O N I T O R I N G

Vibration monitoring systems have two constituent parts: The sensing element The monitoring equipment The sensing element provides an output proportional to the level of vibration being monitored. The output will depend upon the type of sensor being used. The range of monitoring equipment available varies from simple alarm devices to real-time spectrum analysers.

3.1

Types of sensor
Piezo-electric accelerometers The piezo-electric accelerometer is widely used for vibration measurement. Its construction consists of a crystal of piezo-electric material to which is attached a seismic mass (See Figure 10). When the crystal is stressed in tension or compression, it generates an electrical charge which is proportional to the acceleration level it is experiencing. Internal circuitry converts this signal into a voltage (mv/g) output or current output (420mA) for data collectors or process control loops. This robust device has no moving parts and offers long term stability and reliability. It has very wide frequency and dynamic ranges and signals can be integrated to give velocity and displacement values. These accelerometers tend to be lower cost than the alternatives and are available for a wider range of arduous applications. eg. high temperature, submersible use and corrosive media.
Figure 10
5

3.1.1

1. Mounting stud 2. Base 3. Piezo-electric crystal

4 3

4. Mass 5. Braided, screened cable

2 1

Piezo-electric technology is the basis of the Trolex TX5630 range of vibration sensors. These are available with standard 100mV/g, ac output or conditioned 420mA output, corresponding to a specific velocity or acceleration amplitude range.

13

3.1.2

Piezo-resistive accelerometers These sensors monitor the force exerted on a beam, by a mass, utilising straingauge technology. The frequency range of this device is lower than piezo-electric versions, but has the advantage of being able to monitor static or dc acceleration levels. Because of its ability to monitor acceleration down to 0Hz, the piezo-electric accelerometer is not as robust as the piezo-electric version. Its use, therefore is not as widespread and the cost is usually higher.

Trolex can supply these sensors to suit specific applications.

Figure 11

3.1.3

Eddy current probes Eddy current probes monitor displacement using a non-contacting or proximity method. The eddy current probe is widely used for measuring distances on static and rotating machines. Both the ac vibration and dc gap can be measured by the non-contact method. The simplicity of the probe lends itself to being used in harsh conditions.

Trolex have a number of eddy current probes capable of monitoring displacement from 0 to 12mm, at frequency from 0Hz up to 10kHz.

Figure 12

14

3.1.4

Contacting displacement sensor There are a number of different types of contacting displacement sensors. The most popular version being the LVDT type.

Figure 13
LVDT Assembly

Machine Housing

Non-metallic tip Shaft surface

The use of these sensors, is usually limited to very specific applications, due to its need to have direct contact with the surface being monitored.

15

3.2

Vibration monitoring equipment

The type of vibration monitoring equipment used will depend upon the type of sensor and the requirements of the monitoring process.

3.2.1

Overall level vibration monitors As the name implies, these instruments measure overall vibration amplitude. Overall vibration refers to the overall or total amplitude summation of all the vibration in the form of acceleration, velocity or displacement parameters. They are used extensively due to their simplicity and cost. Although most of these instruments are not able to display or store either spectra or time waveforms and have limited operating frequency ranges. Many early instruments have no method for recording the vibration and this had to be done manually. However, instruments such as the Trolex TX9042/4 now have both datalogging and communication facilities allowing trending of general vibration levels to be more easily recorded. A good preventative maintenance program is likely to use both overall monitoring and specific analysis (e.g. FFT Analyser).

3.2.2

FFT Programmable Data Collectors There are a number of FFT analysers available in the market, which allow vibration to be monitored in the frequency spectrum, simplifying diagnosis of machine problems. However, due to cost, these instruments are rarely used for fixed installations. They are usually used as portable instruments to diagnose problems found by overall vibration level analysis instruments. Trolex accelerometers (TX5630) can be connected directly by industry standard FFT analysers.

3.2.3

Real-time Spectrum Analysers Because of the processing power required, most FFT analysers work on stored vibration readings. If real-time monitoring is required, a real-time spectrum analyser should be used. However, with the constantly increasing capabilities of todays data collectors, they are no longer an absolute necessity for a complete condition monitoring programme and their cost and size usually prohibits use in all but exceptional circumstances. The Trolex range of vibration sensors (TX5630) can be used with most industry standard spectrum analysers.

16

4. H O W

T O S E L E C T A N D U S E T H E C O R R E C T V I B R AT I O N

EQUIPMENT

4.1

Selection criteria for sensors

The following items should be considered when selecting a suitable sensor for the application:

SENSITIVITY RANGE Sensitivity is the capability of the sensor to determine the amplitude of vibration (displacement, velocity, or acceleration) from the amplitude of the voltage signal. For example, an accelerometer may have a sensitivity of 100mV/g. This means that if this 100mV/g accelerometer saw 0.1g at a particular frequency, it should convert this vibration to an output of. 0.1 1 FREQUENCY RANGE Frequency range is the measuring capability of the sensor from a low limit to a high limit of frequency. Each sensor has its own frequency range which will need to be matched to the process being monitored. Typically, the frequency response of the sensor is specified at an amplitude tolerance such as 5%, 10% and/or 3dB. x 100 = 10mV

USABLE TEMPERATURE RANGE This is the minimum and maximum temperature that a sensor can withstand without significantly affecting its response capabilities. This is especially important when selecting sensors to be mounted permanently on machinery that is subjected to very high or low temperatures.

MEASUREMENT DIRECTION Piezo-electric sensors measure only in the mounting direction axis (with only a small percentage reaction to vibration in directions perpendicular to the mounting axis typically 3% to 6%).

SENSOR POWER SUPPLY Trolex TX9042/4 Programmable Sensor Controller and TX9130 Programmble Trip Amplifier have been specifically

designed to interface to the whole range of Trolex TX5630 Vibration Sensors as well as other industry standard sensors. Care should be taken when connecting sensors to other monitoring equipment as some vibration sensors have very specific requirements.

17

 MOUNTING SENSITIVITY There are many ways to mount sensors (handheld probes, magnetic connectors, permanent stud mounts, adhesive mounts, etc.). Each has a significant effect on the ability of the sensor to measure the vibration accurately and produce repeatable results. This one fact is often critical to obtaining accurate and repeatable data (section 4.4).

ELECTRICAL INTERFERENCE Accelerometers can be extremely sensitive to electrical interference. Good electrical practice should be followed in earthing machinery and instrumentation grounding to ensure correct operation (see section 4.6).

18

4.2

Vibration sensors available from Trolex

Trolex can provide a range of piezo-electric vibration sensors as standard. In addition, piezo-resistive and eddy-current sensors can be provided to specific order.

4.2.1

ac Output Versions (TX5631, TX5632 and TX5633) This range of vibration sensors is available with an ac output voltage compliant with industry standard ICP interface. This provides for precision vibration measurement for machine condition monitoring. These sensors feature:
ac output signal for discreet vibration frequency monitoring.

rms indication of acceleration velocity, or displacement. Programmable function and setpoint alarms when used with TX9137 Programmable Trip Amplifier. TX9042/4 Programmable Sensor Controller. High integrity vibration monitoring for; generators, pumps, compressors, turbines and engines. Intrinsically Safe versions available for hazardous areas.

Technical Details
Sensing Principle: Frequency Range: Sensitivity Range: Linearity: Temperature Limits: Supply Voltage: Material: Protection Classification: Mounting: Ex Certification: Piezo electric accelerometer. 1Hz to 20kHz. 100 mV/g. 1%. 25C to 140C. 12 / 24V dc. Stainless steel. IP67. M8 x 8 stud. EEx ia I. EEx ia IIC T6. Options: Cable length to specification. MS plug and socket connection. (TX5633). (TX5632).

Order Reference
TX5631 VIBRATION SENSOR ac. (GENERAL PURPOSE). VIBRATION SENSOR ac. (I.S. GROUP II). VIBRATION SENSOR ac. (I.S. GROUP I).

TX5632

TX5633

19

4.2.2

Conditioned 420mA versions (TX5634 TX5639) This range of vibration sensors provides a 420mA output proportional to a fixed range of either velocity or acceleration. This allows the sensor to be connected to a PLC or other standard monitoring equipment. These sensors feature:
Programmable function and setpoint alarms when used with TX9131 Programmable Trip Amplifier or TX9042/4 Programmable Sensor Controller. High integrity vibration monitoring; generators, pumps, compressors, turbines and engines. Intrinsically Safe versions available for hazardous areas.

Technical Details
Sensing Principle: Frequency Range: Linearity: Temp. Limits: Analogue Output: Supply Voltage: Material: Protection Classification: Mounting: Ex Certification: Options: Piezo electric accelerometer. 2Hz to 1KHz. 1%. 25C to 80C. 4 to 20mA. 12 / 24V dc. Stainless steel. IP67. M8 stud or quickfit adaptor. EEx ia I. EExia IIC T6 Cable length to specification.

Order Reference
TX5634 VIBRATION SENSOR/TRANSMITTER. Acceleration (I.S. GROUP II). VIBRATION SENSOR/TRANSMITTER. Acceleration (GENERAL PURPOSE). VIBRATION SENSOR. Acceleration (I.S. GROUP I).

TX5635

TX5636

TX5637

VIBRATION SENSOR/TRANSMITTER. Velocity (I.S. GROUP II). VIBRATION SENSOR/TRANSMITTER. Velocity (GENERAL PURPOSE). VIBRATION SENSOR. Velocity (I.S. GROUP I).

TX5638

TX5639

20

4.3

Selection of monitoring equipment

The range of vibration sensors provided by Trolex has been designed to interface to a large range of monitoring equipment. This can be specific vibration equipment such as dataloggers and FFT analysers or general equipment such as PLCs.

Trolex can also provide a range of equipment designed to provide a cost effective vibration monitoring solution, from a single point alarm to a comprehensive multi-point, datalogging and communicating system.

21

4.3.1

TX9030 Programmable Trip Amplifiers These instruments can be used to provide a readout of vibration level and provide a relay output contact, to alarm when levels exceed a pre-determined value. There are versions to accept the ac signal from vibration sensors as well as the conditioned output from 420mA sensors.
TOTAL PROGRAMMING VERSATILITY IN A SINGLE UNIT WITH DIRECT FINGERTIP SELECTION OF ALL INPUT AND OUTPUT CONTROL AND DISPLAY FUNCTIONS. Easy to operate 'menu' programme. Large digital LCD panel with function display and input signal display. Analogue or frequency inputs. Dual set point, relay output. Latch or auto-reset. Hysteresis selection. Power-on delay. Output time delay. Signal update selection. Permanent data memory. Engineering units menu. 4 to 20mA repeater signal.

Technical Details
Temperature Limits: Display: Supply Voltage: Input Signal Capability: Output Relays: 5C to 50C. LCD, dot matrix, 16 characters. 24V dc at 50mA. Current (4 to 20mA). Frequency (0.1Hz to 5KHz). 2 with programmable set points, time delay hysteresis, rising/falling, latching/pulsing, power on delay, configurable time delay. 0 to 120 seconds. 0 to 99%. 0 to 99%. Menu of 30 standard units, (g, mm/s, ft/s, etc.). Programmable scale/zero. Signal bar graph, set point value display. Signal tendency, alarm indicators. Signal line monitor, peak/low indicator.

Order Reference
TX9031 PROGRAMMABLE TRIP AMPLIFIER. (4-20mA, Panel/DIN Rail Mount). PROGRAMMABLE TRIP AMPLIFIER. (ac, Panel/DIN Rail Mount).

TX9037

Signal Update Period: Set Point Adjustment: Hysteresis Adjustment: Information Display:

Options:

4 to 20mA Repeater Output Signal.

22

4.3.2

TX9130 Programmable Trip Amplifier This range of Programmable Trip Amplifiers is certified, Intrinsically Safe, for use in Group I (mining) hazardous areas. These instruments can be used to provide a readout of vibration level and provide a relay output contact, to alarm when levels exceed a pre-determined value. There are versions to accept the ac signal from vibration sensors as well as the conditioned output from 420mA sensors.
TOTAL PROGRAMMING VERSATILITY IN A SINGLE UNIT WITH DIRECT FINGERTIP SELECTION OF ALL INPUT AND OUTPUT CONTROL AND DISPLAY FUNCTIONS. Easy to operate 'menu' programme. Digital LCD panel with function display and input signal display. Analogue or frequency inputs. Dual set point, relay output. Latch or auto-reset. Hysteresis selection. Power-on delay. Output time delay. Signal update selection. Permanent data memory. Engineering units menu.

Technical Details
Temperature Limits: Display: Supply Voltage: Input Signal Capability: Output Relays: 5C to 50C. LCD, dot matrix, 16 characters. 12V dc (nominal). Current (4 to 20mA). ac Vibration (1 to 20KHz). 2 with programmable set points, time delay hysteresis, rising/falling, latching/pulsing, power on delay, configurable time delay. 0 to 120 seconds. 0 to 99%. 0 to 99%. Menu of standard engineering units, (g, mm/s, ft/s, etc.). Programmable scale/zero. Signal bar graph, set point value display. Signal tendency, alarm indicators. Signal line monitor, peak/low indicator. EEx ia I.

Options
DIN RAIL MOUNT Material: ABS. Protection: IP20. PANEL MOUNT Material: ABS. Protection: IP65. 19" RACK MOUNT Material: ABS. Protection: IP20.

Signal Update Period: Set Point Adjustment: Hysteresis Adjustment: Information Display:

Order Reference
TX9131 PROGRAMMABLE TRIP AMPLIFIER. 4 to 20mA. PROGRAMMABLE TRIP AMPLIFIER. ac.

TX9137

Certification: Options:

Repeater Output Signal. (0.4 to 2V/ 4 to 20mA/ 5 to 15Hz)

23

4.3.3

TX9042/4 Programmable Trip Amplifier The TX9042/4 is capable of monitoring up to 8 channel of vibration. However, its great flexibility is that it is capable of monitoring a large range of input signals. The TX9042/4 is capable of monitoring not only vibration, but a wide range of condition monitoring sensors. Datalogging and communication facilities allow for trending of vibration. This simplifies monitoring of machine deterioration.

MONITORS ANY COMBINATION OF EIGHT ANALOGUE SENSORS OR UP TO SIXTEEN ON/OFF DIGITAL INPUTS OR FREQUENCY INPUTS. Menu operated function selection: Scale, units and offset. Four programmable output relays: Set points, time delay hysteresis, relay function selection. Simultaneous display of input signal levels. Signal tendency display. Signal bar graph. Peak/low data display. Datacomms for RS232/RS485. TTL DIGITAL (MODBUS). Sensor data exchange ability. 26,000 point data logging. Line monitoring. Signal fault alarm. Choice of mounting formats.

Technical Details
Mounting: Display: DIN rail/ Front of panel/ 19" rack. LCD, dot matrix, 20 characters x 4 lines. Eight way simultaneous display with individual channel close-up facility. 12V/24V dc at 120mA. Current (4 to 20mA). Voltage (0 to 10V). Thermocouple (Type J or K). Platinum Resistance (PT100). Bridge (0.1mV/V to 100mV/V). Digital (on/off). Frequency (0.1Hz to 5KHz). ac Vibration (1 to 20KHz). 2 per channel. Programmable set point level, time delay, hysteresis, rising/falling, latching/pulsing, power on delay. 4, with configurable function grouping. 0 to 99%. 0 to 99%. Menu of 30 standard engineering units, (bar, m/s, rpm, etc.), programmable scale/zero, signal bar graph, signal tendency, signal fault alarm, peak/low data retention, channel reference text entry. 26,000 point data log event recording on each channel. EEx ia I. RS232, RS485. TTL DIGITAL.

Supply Voltage: Input Signal Capability:

Set Points:

Output Relays: Set Point Adjustment: Hysteresis Adjustment: Information Display:

Order Reference
TX9042 PROGRAMMABLE SENSOR CONTROLLER. (Group I Mining). PROGRAMMABLE SENSOR CONTROLLER. (General Purpose). Data Log: Ex Certification: Data Comms:

TX9044

24

4.3.4

TX2100 Commander The TX2100 has the same functionality as the TX9042/4, but has the added capability of increasing the number of points that can be monitored.

Bus expandable to 256 channels of I/O. Configurable input signals and output drivers. Programmable sensor response functions. Programmable logic control functions. Data logging. Datacomms for distributed systems. Intrinsically Safe for hazardous area operation.

Sensor Input Signal Values Individual or multisensor display with signal bargraph trending and text entry for sensor duty. Control Output Signal Status Individual or simultaneous display of output function and text entry for control duty. Data History Data storage of Peak/low values and graphical trending. Data logging of sensor data and output events with time, date and identification. Sensor Signal Function Programming Characterisation of sensor response including; Rising/falling signal, Hysteresis, Scaling, Units, Offset, Damping, Sample Rate and Fault monitoring. Commandbus Extendible I/O channel communication bus with power supply distribution to each channel. Datacomms Proprietory datacomms for distributed monitoring and control systems with conventional or optic fibre transmission. MODBUS SAP ETHERNET

25

4.4

How to mount a vibration sensor

There are 5 commonly used sensor mounting methods. These are shown below, along with the maximum acceptable frequency that can be monitored together with the typical resonant frequency of the mounting method.
Maximum Acceptable Frequency Resonant Frequency (Mount)

Stud mount Quickfit stud mount Magnetic mount Handheld Adhesive mount

16kHz 6kHz 7.5kHz 800Hz 9kHz

30kHz 10kHz 12kHz 1.5kHz None

Figure 14

Silicone Grease

Flat Mounting Suface

Adhesive bond to flat surface

STUD (BEST)

MAGNET (GOOD)

PROBE (POOR)

ADHESIVE (VERY-GOOD)

Incorrect mounting can cause the readings obtained from the sensor to be inconsistent.

26

4.4.1

Stud mount Stud mounting is used for permanently mounted sensor applications. Sometimes, an adhesive will be used in combination with mounting thread to prevent the sensor from losing its torsion under vibration conditions. Stud mounting is not always practical for all applications, but it is the preffered method.

Figure 15

Integral Conical

Integral Stud

In order for the vibration sensor to reproduce precisely the vibration generated by the machine under surveillance, it is imperative that its mounting face, in effect, becomes a solid part of the structure. The sensor mounting face should see a flat surface at the machine interface, and not an irregular or curved plane, which would compromise the correct transmission of the vibration. Avoid the common pitfalls below.

Figure 16

Curved Surface

Flat Surface Tapped hole too shallow Tapped hole has clearance

It is also recommended that the sensor cable is looped and then tied with a cable tie to the main body in order to avoid excessive wear.

Figure 17

Loose cable causes vibration and wear

Secure Cable

27

4.4.2

Adhesive mount Adhesive mounts should be utilised as an alternative to stud mounting where a stud cannot be fitted. Great care should be taken in preparing the surface when using an adhesive, to ensure a permanent bond, because a bad joint will work loose over a period of time. An alternative to magnetic or portable mounts is to glue a quickfit mount onto the machine. The type of adhesive must be appropriate for the materials and the environment in which it is to be used. The adhesive must also provide a rigid base. Soft set adhesive will cause the higher frequencies to be absorbed.

Figure 18

Quickfit Glue

4.4.3

Magnetic mount Magnetic mounts are generally used with portable diagnostic instruments when data collecting. The magnetic mount does give repeatable data over the frequency range for which it is suitable. An alternative to magnetic or portable mouts is to glue a quickfit mount onto the machine.

28

4.4.4

Quickfit stud mount Quickfit stud mounts are also extensively used for collecting data with portable instruments. Repeatability of readings within its acceptable range is good, making it suitable for use with most data collectors.

Figure 19

Quickfit Stud

4.4.5

Handheld This is the least acceptable method of mounting and is only really useable on vibration frequencies below 1kHz. A handheld probe is of use when other mounting options cannot be used.

29

4.5

Where to mount the sensor

In order to ensure that vibration problems are diagnosed correctly, it is essential that information received from sensors is not only good, but representative of the actual vibration on the machine part being monitored. Correct selection of the sensor for the vibration being monitored is imperative, but equally important is the mounting of the sensor. When monitoring bearings, the sensor should be located as close to the source of vibration as possible. These should be within the load zone of the bearing. This is particularly important where high frequency components of vibration are being monitored. Ideally, horizontal (1) and vertical (2) measurements should be taken. However, where cost is significant, a compromise solution of a sensor fitted at 45 to the horizontal can be used (3).

1
Figure 20

Sensors should be mounted such that the axis of the sensor passes through the centre of the shaft and as close as possible to the shaft centre line. Readings taken on foundations are not representative of shaft and bearing vibration and should only be used when structure vibrations are being monitored. Care should be taken to ensure that the sensor is mounted on a substantial part of the machine, such as the motor case. Avoid mounting on thin sheet metal structures such as outer casings.

30

Figure 21
GOOD AND POOR MEASUREMENT LOCATIONS.

Vertical

Axial

Horizontal

TYPICAL MACHINE WITH FABRICATED BASE

Choose foot for axial measurement if good accessible locations near shaft are not available.

PILLOW BLOCK BEARING

MOTOR DRIVE END

MOTOR FAN GUARD END

31

4.6

Cabling to the sensor

Because of the low level of signal produced by most vibration sensors, it is important that good electrical practice is followed in cabling the sensor, on fixed installations. Accelerometers are usually fitted with screened PVC cable encased in an overbraided stainless steel sheath. This offers excellent protection for the arduous environment in which vibration sensors are used. However, long lengths can be difficult to control on a stud-mounted sensor. Options include connector versions, quickfit mounts and a local junction box. It is recommended that the cable is looped (where possible) and tied to the sensor. This avoids excessive wear and stress at the cable/sensor junction.

Figure 22

Use a cable tie

In order to avoid electrical pickup through the case of the sensor from the machine being monitored, the machine should be properly earthed in compliance with local regulations. If a good earth is not possible, the sensor and the cable overbraid should be electrically isolated from the machine.

Figure 23

Insulating Blocks

The screen of the cable should be connected to earth at the monitoring equipment. IT SHOULD NOT BE EARTHED AT THE MOTOR. The cable overbraid should be left unconnected
Sensor

Figure 24
TX9042 Programmable Sensor Controller

32

5. T Y P I C A L

A P P L I C AT I O N S F O R

TROLEX

V I B R AT I O N

MONITORING EQUIPMENT

5.1

Underground booster fan monitoring utilising the Trolex TX9042 Programmble Sensor Controller and the TX5633 vibration sensor
Figure 25
1. Non-Drive End 2. Drive End 3. Drive End 4. Non-Drive End

Motor

Fan

Trolex TX5633 vibration sensors are mounted at 45 to the horizontal on each of the bearings on the fan (positions 1 to 4). These are connected to the TX9042 as shown below.
TX5633 Fan DE TX5633 Fan NDE

Figure 26

SCN

Core

SCN

Core

19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36

TX9042/4 Programmable Sensor Controller

Acceleration Channel Fan DE

Velocity Channel Fan DE

Acceleration Channel Fan NDE

Velocity Channel Fan NDE

Acceleration Channel Motor NDE

Velocity Channel Motor NDE

Acceleration Channel Motor DE

Velocity Channel Motor DE

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
Core SCN Core SCN

0V

Power

+12V Supply

TX5633 Motor NDE

TX5633 Motor DE

33

In figure 26 channels 1,3,5 and 7 on the TX9042 Programmable Sensor Controller are configured to monitor velocity (in mm/s) in the frequency range 10 to 500Hz. Channels 2, 4, 6 and 8 are configured to monitor acceleration (in g) in the frequency range 1kHz to 20kHz. The fan is running at 1500 rpm giving a fundamental of 25Hz. After the fan has been given time to run in, the vibration levels on each channel should be monitored using an FFT analyser to ensure that there are no vibration levels of concern. The resulting vibration levels on the TX9042 should be recorded and the alarm levels set at a suitable margin of excess vibration.

Velocity is used to monitor out-of-balance on the fan. This can be due to a number of causes:

Misalignment of the shaft Imbalance of the blades Dust build-up on the blades Chipped or broken blades
Acceleration is used to monitor bearing breakdown. This can be a result of a number of conditions, such as lack of lubrication or long term wear and tear. By looking at the trend of velocity and acceleration, the deterioration of the fan, especially with respect to its bearings, can be monitored. As well as monitoring excess vibration levels, the TX5633 (in conjunction with the TX9042) can be used to remotely confirm that the fan is running. A moderate level of vibration, indicates a healthy fan, running at its normal speed. Lack of vibration would indicate a signal fail, or stationary fan.

34

5.2

Pump monitoring (non-hazardous areas)

Figure 27

Sensor 1 Loose Bolt Sensor 2

In this application, two TX5631 sensors are mounted on the outlet end of the pump (one vertical, one horizontal), to monitor: out-of-alignment, mounting movement, or loose fixings. The TX5631 Vibration Sensors are connected to two channels of the TX9044 Programmable Sensor Controller which is set-up to monitor velocity in the range 10 to 500Hz. The pump is rotating at 3000 rpm giving a fundamental frequency of 50Hz.

Figure 28

19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36

TX9042/4 Programmable Sensor Controller

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
Core SCN Core SCN

0V +24V

Sensor 1

Sensor 2

35

Alarm levels on the TX9044 are set up according to BS7854 Part 1, (ISO10816-1) to monitor vibration severity. As the TX9044 has spare channels available, temperature and pressure monitoring on the pump can easily be accommodated using simple PT100 probes and pressure sensors.

Figure 29

TX6114 Outlet Pressure

TX6114 Inlet Pressure

TX2072 Pump Bearing Temp

TX2072 Liquid Temp

19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
4-20mA Module 4-20mA Module PT100 Module PT100 Module

TX9042/4 Programmable Sensor Controller

ac Module

ac Module

ac Module

PT100 Module

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

TX5631 Pump Vibration (vertical)

TX5631 Pump Vibration (horizontal)

TX5631 Motor DE

TX2072 Motor Gearbox Temp

As with the previous example, quiescent vibration monitoring can be used to remotely confirm that the pump is running or stopped. The TX9044 can also be used to remotely stop/start the pump, via a data communication link and the built-in output control relays.

36

5.3

Hazardous area, vibration monitoring

When the equipment to be monitored is in a hazardous area, certified safe equipment needs to be used. The Trolex TX5630 Vibration sensors are certified, Intrinsically Safe, for use in Group II hazardous areas. However, Trolex monitoring equipment is intended for mounting in the safe area. In order to connect to the sensors in the hazardous area, zener safety barriers or isolators need to be used between the sensors and the monitoring equipment. The diagrams below give typical barrier and isolator options.

Figure 30

1
Core

3 4

MTL728

1 2

Core

2 3 4
TX9044 Programmable Sensor Controller

Scn

Scn

IS earth

TX5632

Zener Safety Barrier

Scn

3 4

MTL787s

1 2
IS earth

Scn

1 2 3 4
TX9044 Programmable Sensor Controller

TX5634 or TX5637

Zener Safety Barrier

Figure 31

5 6 7 8
TX5634 or TX5637

MTL3041

1 2 3 4
+24V 0V

1 2 3 4
TX9044 Programmable Sensor Controller

Isolators

37

5.4

Screening and bunker outfeed monitoring

Vibratory screens are used for the grading of product in many mining and quarrying applications. Product is introduced onto a vibrating sieve and small product passes through whilst large product is screened to the next stage. Vibrating pans are used on the outfeed to ensure that product does not block the outfeed chutes. A Trolex TX5630 Vibration Sensor mounted on the vibratory screen, can monitor the operation and condition of the screen, when connected to a Trolex TX9042/4 Programmable Sensor Controller. By setting window alarms, the system can locally or remotely monitor that the screen is running correctly and that vibration levels are not excessive. By trending vibration levels, deterioration in the condition of the screen and its mounts can be monitored. Similarly, the vibrating pans on the outfeed can be monitored for both operation and excessive wear.

Figure 32

Infeed Conveyor Screen

Small Aggregate Large Aggregate

Bunker 1

Bunker 2

Vibration Sensors

Outfeed Conveyors

Vibrating Pan
Outfeed Conveyors

38

5.5

Conveyor drive monitoring

Figure 33

NAMUR Proximity Sensors

GEARBOX

TX2072 Temperature Sensors

MOTOR

TX5631 Vibration Sensors

A conveyor is the backbone of any product clearance system and a breakdown of this is likely to be costly. Utilising Trolex vibration monitoring equipment, the plant engineer can obtain an early indication of impending motor and gearbox failure. Temperature monitoring can also be utilised to save catastrophic failure by interlocking an excessive temperature alarm setpoint with the motor drive control. The diagram shows how the vibration sensors and temperature sensors connected to a TX9044 Programmable Sensor Controller and how this could be used to disable the conveyor under high temperature conditions or excessive vibration.
Figure 34

NAMUR Sensors (speed) Conveyor "running" contactor

19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36

TX9042/4 Programmable Sensor Controller

To conveyor drive stop circuit 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Vibration visual alarm 0V +24V

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

TX2072 TX5631 TX2072 (2 wire) (2 wire) Vibration Temperature Vibration Temperature Sensor Sensor Sensor Sensor (motor) (motor) (gearbox)

TX5631

39

NAMUR sensors can be used to indicate conveyor speed and belt slip, by monitoring the speed of both the motor and an idler wheel. If the temperature inputs are programmed to latch one of the output relays when over temperature occurs, the output relay could be interlocked with the conveyor stop circuitry to lockout the conveyor. The latched relay would then have to be manually reset before attempting to restart the machine. An input from the conveyor drive contactor can give confirmation that the conveyor is running. The two spare relays could be used for remote stop/start of conveyor if data communication was available.

NB. Care should be taken that adequate warning is given if conveyors are being started remotely (e.g. Pre-start alarm).

40

APPENDIX A

U N D E R S TA N D I N G

A N D U T I L I S I N G T H E V I B R AT I O N

I N F O R M AT I O N O B T A I N E D

It is beyond the scope of this document to give full explanation on how vibration can be used to analyse problems on a machine. However, as an example, an explanation will be given on how vibration can be used to monitor bearing and gearmesh deterioration and imbalance on a ventilation fan. Ventilation fans are used in critical areas such as underground mining and tunnelling, where natural ventilation is not sufficient to either dilute noxious/explosive gases or to ensure a sufficient supply of oxygen.

Figure 35

Motor

Fan

There are 3 areas of interest in monitoring vibration on the above installation.

VIBRATION AMPLITUDE

Figure 36

1 2
100Hz 1kHz

10kHz

FREQUENCY

Although these areas are not always as discreetly defined as shown here, they have been separated for the purposes of this example.

41

IMBALANCE
is identified at a frequency equal to the shaft rotational frequency x No. of teeth on gear Lubricant

GEARMESH DETERIORATION

Figure 37

VIBRATION DATA FAULT DIAGNOSIS

is identified at a frequency equal to (1X) the shaft rotational frequency (motor speed)

INITIAL BEARING DETERIRATION/ LUBRICATION DEFICIENCY

is identified as broadband spectral baseline activity and may be expressed as I.F.B and/or H.F.B.

BEARING Drive Gear Driven Gear

42
UNITS VELOCITY mm/sec ACCELERATION (g) UNITS ACCELERATION (g)

0 - 1000 Hz SPECTRUM

1 - 20 kHz SPECTRUM

MISALIGNMENT/INSECURITY

BEARING DETERIORATION
is identified as broadband spectral baseline activity and at the bearings calculated fault frequencies. ie. Cage, Roller Inner and Outer Race. BEARING

is identified at 2x, 3x and 4x the shaft rotational frequency

5.1

Imbalance
Imbalance occurs because the machine is not perfectly balanced about the shaft centre line. This can be caused during manufacture, installation or during operation (eg. debris build-up on a fan blade). Imbalance will occur at the rotational frequency of the fan. So on a fan rotating at 1500 rpm, imbalance will occur at 25Hz. As the imbalance increases, it will be seen as increase in the vibration signal at 25Hz. This will require a monitoring instrument capable of displaying the signal in the frequency domain (eg. FFT analyser). If a broadband alarm monitor, such as the Trolex TX9042 Programmable Sensor Controller is used, with a fixed, low pass filter then the general overall level of vibration will be seen to increase. This can be compared to an alarm set-point, as suggested by BS7854 Part 1. This alarm indication would suggest that a spectrum analyser should be employed to define the fault more specifically.

5.2

Gearmesh problems
Vibration due to the gear teeth will be seen at the rotational frequency multiplied by the number of teeth. So, on a machine with rotational frequency 1500 rpm and
r

30 teeth on the wheel, the fundamental vibration frequency is about 750Hz. As the teeth start to deteriorate, the amplitude of the vibration, at the 750Hz fundamental, will increase. This would easily be picked up with an instrument such as an FFT analyser. An alarm instrument such as the Trolex TX9042 Programmable Sensor Controller, could also be used to indicate that the level of vibration, around the frequency of interest, has increased.

5.3

Bearing breakdown
Bearing noise, due to imperfections in the bearing, will start at high frequency (>1kHz). Bearing deterioration can be caused by: Poor quality of the bearing Inadequate lubrication Contaminated lubrication Poor installation As the bearing starts to deteriorate, larger imperfections occur, increasing the amplitude of the vibration and at the same time reducing the frequency of the vibration. Over time, the signal will change as shown in Figure 30.

43

Figure 38

2 1

1kHz

10kHz

The Trolex TX9042 Programmable Sensor Controller can be used to monitor the increase in broadband vibration, whilst disregarding the change in frequency.

44