Vibration Monitoring & Analysis

By

Training Program on
WBPDCL Simulator
PREPARED BY

T.M.JOARDAR Sr. Manager (Mech) SAGARDIGHI THERMAL POWER PROJECT

What shall we learn?

Vibration Fundamentals Sensors and Instruments

Vibration Standards
Implementation

Vibration analysis Typical problems

Vibration Monitoring
Applications

Fans / Blowers Compressors / Engines Turbines / Alternators Pumps Gear Boxes / Bearings Ball Mills Electric Motors And a whole lot of other items

Vibration Monitoring

Problem Identifications
Unbalance Misalignment Mechanical Looseness Antifriction / Sleeve Bearing Defects Gear Defects Resonance

Vibration Monitoring

Problem Identifications
Belt Defects Impeller / Blade Defects Bent Shaft Electrical Problems Reciprocating Machines Sometimes static machines and process evaluation

Vibration Monitoring
What is Vibration ? It is the motion of mechanical parts back and forth from its position of rest /neutral position.

VIBRATION FUNDAMENTALS

DISPLACEMENT WAVEFORM
90 Upper Limit

DISPLACEMENT Neutral Position TIME 18 0

Lower Limit Period(T) (1 complete cycle) 270

Vibration Monitoring
What causes Vibration ?
Induced Force & Freedom for Movement

Vibration Monitoring
Harmful Effects of Excess vibration

Increased load on Bearings: Reduced Bearing Life Higher Forces on Mountings: Foundation Loosening and Damage of Support Structure Increased Stresses on Machines : Risk of fatigue on components

Vibration Monitoring
Harmful Effects of Excess vibration

Decreased Equipment efficiency. Reduced Output Quality. Increased Maintenance Cost due to more Component Failures and Unplanned Operations Unsafe Operating Environment

Vibration Monitoring
Fundamental Realities

All Machines while running vibrate. An increase in vibration level is a sign of trouble Each trouble will create vibration in its own unique way - with different characteristics

Characteristics of Vibration

Vibration characteristics are

Amplitude
Displacement Velocity Acceleration

Frequency Phase

Hz or CPM Angle or clock face

FREQUENCY

DISPLACEMENT AND FREQUENCY FROM THE TIME WAVEFORM

Upper Limit DISPLACEMENT TIME Neutral Position

Lower Limit Period(T) (1 complete cycle) Frequency =

1 1 = = Period T

Cycles Second
13

Vibration Monitoring
Other modes

Kurtosis Spike Energy Shock Pulse Measurement SEE HFD Acceleration Enveloping Velocity Enveloping

What is Phase?

The position of a vibrating part at a given instant with reference to a fixed point or another vibrating part. The part of a vibration cycle through which one part or object has moved relative to another part.

The unit of phase is degree where one complete cycle of vibration is 360 degrees.

Vibration Phase

16

Phase
Additional Illustration on phase

17

PHASE AN ILLUSTRATION ON MOTOR

30 Micron 10 degrees 32 Micron 10 degrees

Shaft centre line moves up and down in a planer fashion

18

PHASE Cont..
30 Micron 10 degrees 32 Micron 190 degrees

Shaft centre line moves up and down in a rocking fashion

19

MACHINE TRAIN MISALIGNMENT

TURBINE G/B HP COMP LP COMP

AXIAL PHASE (degrees)

0 10 12 8

5 12 10 6

15 22 20 16

18 24 22 20

198 210 208 200

215 220 218 210

Note: All phase readings corrected for pickup direction

Comparing Overall Levels Across Mounting Interfaces

21

Phase application

A B C

5 Microns, 10 degrees 7 Microns, 12 degrees 15 Microns, 155 degrees Bolt at C is loose

22

Unit of Measurement?

Displacement - Microns(um) Velocity - MM/Sec Acceleration - g Acceleration Envelop g-Env Spike Energy g-SE

Vibration Monitoring
Amplitude Descriptors RMS :Energy contained in wave (Proper measurement parameter) Peak :1.41*RMS (Instruments are calibrated by some companies in Peak) Peak-To Peak :2* Peak Average :Area under wave

Parameter Selection

Frequency sensitivity
Displacement Velocity Acceleration <600CPM 600-60,000CPM >60,000CPM

Spike Energy/SEE

Ultrasonic range

Disp. vs Velocity vs Acceleration

Displacement
Sensitive to low frequencies.Good guide for imbalance & other low frequency faults.

Velocity
Has average sensitivity throughout the frequency range.Reasonably sensitive to imbalance,misalignment,looseness and later stages of rolling element bearing damage.

Disp. vs Velocity vs Acceleration

Acceleration
Sensitive to high frequencies.Good guide for rolling element bearing damage,gear related problem & cavitations etc.

Vibration Monitoring
Displacement
Sensitivity to Low Frequencies Good guide for imbalance & other low frequency faults

Parameter Sensitivity to Frequency

Acceleration
Sensitivity to High Frequencies Good guide for Rolling element bearings

Velocity
Have Average sensitivity throughout the frequency range Reasonably sensitive to imbalance, misalignment, Looseness and Rolling element Bearings

Vibration Monitoring
Velocity

Displacement

Acceleration

Notes

30