Systematic Approach to Solving Vibration Problems

Collection of data
Collection of data
Right type to define problem Data Formats and Vibration Parameters Not too much but not too little

Tendency to get caught in process of data collection than to solve problem

Modern instruments provide too much data too easily Tendency to accumulate than analyze. Failure to apply simple logic to data collection.

Systematic approach needed

It is not taking a standard set of data for all situations. It is an adaptive process Difficult to think ahead all data that might be needed. Determining what data to collect next based on data just collected. Analyst needs to know "if" and "what type" of data is needed.

Eleven Steps to Good Vibration Analysis and Problem Resolution

1. 2. 3. 4. 5. 6. 7. 8. Defining the problem Machine history Machine details Visual inspection of machine Quick assessment Phase the forgotten parameter H, V, A, Frequency Plots at each bearing point Determine if vibration is directional or nondirectional 9. Time Waveform / Orbit Analysis 10. Bearing Analysis 11. Frequency confirmation

Defining the Problem

Frequent Component Failures ?
Bearings Couplings Seals Impellers

Frequent Structural Failures ?

Bearing housing / brackets Foundation

Vibration too high ? Too Noisy ? Doesn't Meet Performance Standards ? Inability to manufacture accepted product quality ?

Machine History - 1
When did the problem start ?
Was there a sudden increase in vibration? Was there a gradual increase in vibration? Did the machine always run rough ? Did the machine ever run acceptably

Any changes in machine speed - Gear box or sheave changes ? Changes in machine load ? Changes in fluid or product characteristics ?

Machine History - 2
Have any changes been made to the machine recently ?

Modifications ?
Bearings / Seals / Rotor Materials of construction Piping / Structural / Foundation New machines in the area

Repairs ?
New parts New spare part supplier?

3. Machine Details - 1
Machine sketch Name plate data including HP, rated speed, max. continuous speed Machine critical speeds Type of radial bearing - sleeve, tilting pad, rolling element Type of thrust bearing - rolling element, tapered land, tilting pad Bearing details such as diameter, number of pads, loading etc.

3. Machine Details - 2
Coupling type and make Input speed / Output speed Number of impeller vanes, diffuser vanes Number of turbine blades in each stage Bearing defect frequencies for rolling element bearings. Gear details - number of teeth and mesh frequencies.

4. Visual Inspection of the Machine - 1

Avoid armchair diagnosis. Do not depend on second hand information or assessment Visit and check machine and surroundings visually. On the machine look for
Sign of looseness - belts, bearing bolts, base bolts Sign of broken / cracked / missing parts - bearing housing, coupling bolts Sign of wear - belts, sheaves, coupling disks / elastomer Leaking seals

4. Visual Inspection of the Machine - 2

Lubricating Oil - pressure, flow, quality Bearing temperatures Operating parameters
Pressures Suction & Discharge are they steady Temperatures Suction and Discharge Steam pressure and temperature

Foundation and surroundings

Foundation cracks Piping vibration Vibration transmitted from nearby machines Pipe supports and hangers.

5. Quick Machine Assessment - 1

Get a quick, overall feeling for the machine's general condition. Listen to any abnormal sounds reported by operators using any listening device Collect overall (filter out) velocity readings Enter values on a machine sketch. Highest vibration level is closest to the problem. If time is limited, focus on suspected problem location.

5. Quick Machine Assessment - 2

Collect overall bearing condition measurements.
High frequency measurements indicate rolling element bearing damage. Enveloped G values Spike Energy Shock Pulse Readings - SPM Meter / SPM Analyzer

If shaft vibration probes are installed measure gap voltages. Check vibration levels at points other than bearings.
Base, foundation, mounting bolts, piping

Background or floor vibration.

6. Phase - The Forgotten Parameter - 1

Phase is very useful for diagnosing
Misalignment / bent shaft Loose bolts / soft foot

Often omitted because measurement requires the installation of a phase reference:

Keyphasor - normally installed on permanent shaft vibration monitoring systems. Difficult to install temporarily. Photocell - It may be necessary to stop the machine to fix a reflecting tape Strobe light - Not necessary to stop the machine. Most suitable for slow motion studies.

6. Phase - The Forgotten Parameter - 2

Phase can be measured with
FFT Analyzers Analog and Digital Tracking Filters Manually Tuned Analyzers

Record phase information alongside vibration on machine sketch. Large phase difference in the two bearings across a coupling indicates misalignment Phase should also be measured at mounting bolts, base plate and foundation

7. Horizontal, Vertical and Axial Spectrum

Collect spectral data at all bearings in horizontal, vertical and axial planes.
Use same measurement locations as for routine monitoring If machine running time is limited focus on high vibration locations.

Use same amplitude scale for all data points.

Helps quick visual comparison of levels at one bearing relative to another

7. Horizontal, Vertical and Axial Spectrum

Select optimum frequency range and resolution
Optimize maximum frequency (Fmax) and number of lines for each location May be necessary to collect several spectra at one measurement point

If necessary, use displacement and acceleration spectra to cover the full frequency range.
Displacement - Low frequencies Acceleration - High frequencies

Collect background vibration data

8. Determine if the Vibration is Directional or Non-directional

Helps to determine if 1X RPM signal is due to unbalance or misalignment.

Unbalance force rotates with the heavy spot.

Vertical and horizontal phase would be 90o apart

Reactionary forces are highly directional.

Misalignment, eccentric machine component, reciprocating forces etc. are directional. Horizontal and vertical phase readings may be same or differ by 180 degrees.

If balancing is attempted without checking phase relationships it would end in failure.

9. Time Waveform Analysis - 1

FFT signal processing assumes the vibration signal is periodic and repetitive. FFT reduces a periodic function into a series of sines and cosines of various frequencies. Most mechanical defects produce nonsinusoidal motions.
Spike due to broken gear teeth. Rolling element bearing defects. Impacts due to looseness

Such transient spikes will be averaged out in the FFT spectrum.

9. Time Waveform Analysis - 2

Impacts that have square wave content will be resolved as a series of odd harmonics. These harmonics may be misinterpreted as looseness Many vibration problems may be missed if only spectral data is considered. Instantaneous time waveform clearly shows the occurrence of impact type events. Time waveform analysis supplements spectral data

10. Rolling Element Bearing Analysis 1 Shock Pulse Method

Earliest method based on high frequency enveloped spectrum It is the only quantitative method Accept / reject criteria based on high rate / low rate shock pulse Can detect poor lubrication / starvation conditions. Guidelines available to identify other impact type events

10. Rolling Element Bearing Analysis 2 Spike Energy Spectrum

Originally developed by IRD Mechanalysis Uses enveloping to eliminate fundamental vibration frequencies. Specific bearing defects stand out clearly in the enveloped spectrum Method not quantitative like SPM. Severity must be judged by comparison with previous readings and past experience

10. Rolling Element Bearing Analysis 3 Enveloped Spectrum

Most data collectors and software can produce enveloped spectrum. Principle nearly same as Spike Energy. Not quantitative - Judgment of severity by experience Additional data collection required at each bearing

11. Frequency Confirmation

Determine if the displayed vibration frequencies are exactly related to machine RPM.
Running speed of motor v/s synchronous frequency 2x running speed of 2 pole motors v/s 2x synchronous frequency.

Use an instrument with strobe light that can be triggered by the vibration frequency. Use True Zoom to get better frequency resolution of problem frequencies Use Time Waveform analysis Collect Synchronous FFT data Collect Time Synchronous Waveforms