Professional Documents
Culture Documents
Contents:
LIST OF ILLUSTRATIONS --------------------------------------------------------------------7
VIBRATION ANALYSIS - AN INTRODUCTION---------------------------------------- 13
Vibration Examples------------------------------------------------------------------------------------------------13
Imbalance--------------------------------------------------------------------------------------------------------13
Misalignment ----------------------------------------------------------------------------------------------------14
Looseness--------------------------------------------------------------------------------------------------------15
Rolling Element Bearing Defects --------------------------------------------------------------------------17
SECTION - FANS--------------------------------------------------------------------------------1
Fans are defined as:----------------------------------------------------------------------------------------------- 1
BALANCING ----------------------------------------------------------------------------------------------------- 1
SHAFT TOLERANCE ------------------------------------------------------------------------------------------- 1
RESONANCE ----------------------------------------------------------------------------------------------------- 1
LIMITS------------------------------------------------------------------------------------------------------------- 1
OTHER REQUIREMENTS ------------------------------------------------------------------------------------- 3
FAN CERTIFICATION ----------------------------------------------------------------------------------------- 3
List of illustrations
Figure 1 Velocity spectrum showing imbalance__________________________________________ 13
Figure 2 - Velocity spectrum showing fan imbalance _____________________________________ 14
Figure 3 Velocity spectrum of misaligned fan - radial _____________________________________ 15
Figure 4 Velocity spectrum of misaligned fan - axial______________________________________ 15
Figure 5 Velocity spectrum from a loose fan drive motor __________________________________ 16
Figure 6 Envelope spectrum of a fan drive motor with loose bearing________________________ 17
Figure 7 Enveloped acceleration spectrum of bearing - inner race defect____________________ 18
Figure 8 Inner race spall _____________________________________________________________ 18
Figure 9 Simple Harmonic Vibration ___________________________________________________ 20
Figure 10 Integration from acceleration to velocity _______________________________________ 21
Figure 11 Integrating to displacement __________________________________________________ 22
Figure 12 Peak -v- RMS _____________________________________________________________ 23
Figure 13 Compression mode accelerometer ___________________________________________ 28
Figure 14 Shear mode accelerometer __________________________________________________ 28
Figure 15 Simple modulation example _________________________________________________ 30
Figure 16 Bearing modulation example_________________________________________________ 30
Figure 17 Demodulation process ______________________________________________________ 31
Figure 18 Enveloping process ________________________________________________________ 32
Figure 19 Fast Fourier Transform _____________________________________________________ 32
Figure 20 FFT - 3D view _____________________________________________________________ 33
Figure 21 Two channel time waveform - bearing defect___________________________________ 34
Figure 22 High frequency waterfall ____________________________________________________ 34
Figure 23 Enveloped acceleration spectrum ____________________________________________ 35
Figure 24 Comparison - velocity to envelope ____________________________________________ 35
Figure 25 Imbalance slide 1 __________________________________________________________ 38
Figure 26 Imbalance slide 2 __________________________________________________________ 38
Figure 27 Imbalance slide 3 __________________________________________________________ 39
Figure 28 Imbalance slide 4 __________________________________________________________ 39
Figure 29 Imbalance slide 5 __________________________________________________________ 40
Figure 30 Imbalance slide 6 __________________________________________________________ 40
Figure 31 Imbalance slide 7 __________________________________________________________ 41
Figure 32 Imbalance slide 8 __________________________________________________________ 41
Figure 33 Imbalance slide 9 __________________________________________________________ 42
Figure 34 Misalignment slide 1 ________________________________________________________ 42
Figure 35 Misalignment slide 2 ________________________________________________________ 43
Figure 36 Misalignment slide 3 ________________________________________________________ 43
Figure 37 Misalignment slide 4 ________________________________________________________ 44
Figure 38 Misalignment slide 5 ________________________________________________________ 44
Figure 39 Looseness slide 1 __________________________________________________________ 45
Figure 40 Looseness slide 2 __________________________________________________________ 45
Figure 41 Looseness slide 3 __________________________________________________________ 46
Figure 42 Looseness slide 4 _________________________________________________________ 46
Figure 43 Looseness slide 5 __________________________________________________________ 47
Figure 44 Looseness slide 6 __________________________________________________________ 47
Figure 45 Looseness slide 7 __________________________________________________________ 48
Figure 46 Looseness slide 8 __________________________________________________________ 48
Figure 47 Looseness slide 9 __________________________________________________________ 49
Figure 48 STANDARD SETUP FOR ANALYSIS OF A RIGHT ANGLE DOUBLE
REDUCTION GEARBOX________________________________________________________ 50
Figure 49 SPECTRUM INDICATING GEAR TOOTH WEAR ______________________________ 52
Figure 50 Significant Loading Indicated on Gearing ______________________________________ 53
Figure 51 Gear Eccentricity and/or Backlash____________________________________________ 53
Figure 52 SPECTRUM INDICATING MISALIGNMENT OF GEARS ________________________ 54
Figure 53 COMPARISON OF TIME WAVEFORM FOR A GOOD CONDITIONED VERSUS A
CRACKED OR BROKEN GEAR TOOTH __________________________________________ 55
Figure 54 Hunting Tooth Frequency ___________________________________________________ 56
Consultants Profile
Ronald Frend B.Sc. Technology
d.o.b. 9th May 1954
Experience Summary
Ron is a registered engineer, and has thirty years of engineering, consulting
and management experience. He rose to a senior management position in
Shell International (Middle East) before opening an engineering consultancy
in England. His entire career has been concerned with practical applications
of maintenance and engineering.
Ron is experienced in a variety of predictive maintenance analytical techniques as well as possessing
management skills suitable to an engineering consultancy and a large multi-national corporation.
Specialized training has also been carried out on the following topics:
Management techniques, Non-destructive testing (petro-chem), Oil tanker cargo operations,
Resistance & gas welding,
Career History
1993-present
Business has involved project design, system implementation, training and ongoing consultancy
support.
Systems installed by Ron include Guardian Over Iconet, Entek Emonitor for Windows (EFW) &
Odyssey, CSI MasterTrend, DLI-Predict ExpertALERT Voyager stand-alone and networked systems
as well as MachineXpert on-line monitoring systems. Inframetrics and Agema systems have also
been installed and operated using the 760, 740, Thermacam 200 and 250 cameras and the Agema
595. The strength of the installations has been partly due to the total integration of all applicable
technologies, vibration, thermography, ultra-sound, tribology as well as several other specialized
techniques. The systems implementations are designed for ease of use of the software and to allow
subsequent modifications without affecting the integrity of the database.
Systems installed by Ron won the last System-of-the-Year Award to be sponsored by P/PM,
winning joint first place and first runner-up (GM Lordstown Fab joint first with Boeing Seattle & GM
Lansing Fab first runner up).
Activities have since broadened to encompass audits, formal training, and third party project design.
Ron has pioneered the use of Potential Failure Analysis a technique in which all possible modes
of failure are examined before a failure occurs. This allows the engineers to put in place monitoring
mechanisms to give advance warning of impending failures.
10
Wavevision Ltd.
1990-1993
Ron jointly started this company in 1989. Wavevision was the first predictive maintenance company
in the U.K. to concentrate its activities in a double profit center, sales and engineering consultancy.
Wavevision worked very closely with Diagnostic Instruments to develop the first data collector with
enveloping / demodulation capability. Many of the contracts for installed systems where won because
of the capability of Wavevision to successfully implement vibration analysis in difficult circumstances.
Contract monitoring and reporting was also carried out for many customers. This involved sending
technicians out to the customers site, taking readings and then carrying out an analysis back at the
head office. Reports were forwarded within 24 hours by fax and (in later years) by email.
Shell International
1983 - 1990
Ron was assigned to Petroleum Development (Oman) as a mechanical engineer in 1983. Rons first
job was to initiate a project to replace the floors on all floating storage tanks in North Oman (55,000
bbl). The project was then expanded to cover all stationary equipment inspections and repairs so that
within two years all statutory and maintenance inspections on tanks, pressure vessels, relief valves,
pig traps and headers and pipelines were scheduled for inspection and scheduled targets were being
achieved.
In 1986 Ron was moved within the section to be in control of condition monitoring and vibration
analysis support. Ron was directly involved with supervision of maintenance and condition
monitoring activities on Rolls Royce Avon, Solar Centaur, GE Frame 5, Ruston TB5000 gas turbines
as well as all other rotating and reciprocating equipment in the oil field production areas. Ron
initiated the installation of a computerised vibration analysis system for the optimal utilization of
maintenance resources. In 1987 PDO initiated a Zero Cost approach to maintenance budgeting in
which every aspect of maintenance and engineering had to be justified instead of (as before)
extrapolating previous years costs. The core component of this budgeting exercise was the condition
monitoring expertise coupled with maintenance engineers direct knowledge of the equipment. This
created a 17% reduction in the overall maintenance budget while production increased by over 15%.
In 1988 Ron was promoted to Head of Surface Support. His responsibilities included the planning
and direct control of all above ground maintenance support in the North Oman concession area
(24,000 square kilometers). His budget was over US$9M with a work force of 4 section heads, 18
supervisors and 144 skilled and semi-skilled men under his direct control. Ron reported directly to
the Head of Operations (North Oman).
1970-1983
Ron was an officer cadet from 1970 to 1974 and eventually rose to the rank of second engineer (with
1st Class Motor Certification) by 1980. Duties included operation and maintenance of all installed
plant on board a variety of ships.
As a Shell Tankers engineer Ron was conversant with petrochemical statutory requirements, practical
application of maintenance and operational activities, control systems, electrical engineering and
distribution (up to 3.3 kV), pumps, turbines, HVAC and all other aspects of engineering in a
petrochemical marine environment.
11
Publications
The Potential Failure Analysis Tree - Its use in the installation of a predictive maintenance
system. Vibration Institute (1994)
12
Vibration Examples
When the novice analyst first carries out vibration analysis he will usually rush out and take a
vibration spectrum using the default parameters set up in the analyzer. We will carry on that
noble tradition and look at some spectra that have been collected from real machines and
show typical examples of common defects.
Imbalance
13
Misalignment
Probably 40% of all bearing and shaft failures are caused by misalignment of the
components creating an extra axial thrust on the bearings.
14
Looseness
Looseness exists when the component is not directly attached to the structure or rotating
element and has a relatively large clearance, allowing the component to rattle.
15
16
17
18
Vibration Theory
The following section is meant as a primer to help the newcomer to vibration analysis
understand some of the terms used and to develop an understanding of the concepts.
To understand the concept of vibration analysis, it is important to realize that the motion of
the measured surface varies with time. The transducer converts the movement into an
electrical signal which is passed to the spectrum analyzer which in turn converts that signal
from the time domain into the frequency domain. The time domain waveform is composed
of a machines response to many individual forces such as imbalance, misalignment, gear
meshing forces, rotating electrical fields, and many other factors. When viewing the time
domain data it can be quite difficult to separate these components of vibration. However, in
the frequency domain it is much easier to separate these elements to determine the
importance of each.
Vibration amplitude is measured using three different parameters, acceleration, velocity and
displacement. The purpose of this section is to describe the relationship between each of
these and how they are used on rotating machinery.
19
(48)
* FREQUENCY
* AMPLITUDE
... Displacement
... Velocity
... Acceleration
one cycle
20
(49)
B
Disp
Peak
Peak
to
Peak
Vel
Disp
Highest
Velocity
Figure 4. Velocity is highest where displacement is zero and is zero
where displacement is maximum. Therefore a 90 phase shift exists
21
(50)
B
Vel
Disp
Accel
Acceleration
Acceleration
Peak
Amplitude
Avg
RMS
Peak
to
Peak
Time
22
(51)
Peak
Amplitude
Avg
RMS
Peak
to
Peak
Time
Amplitude
Peak
RMS
Peak
to
Peak
Time
Complex Waveform
23
What is an FFT?
The fast Fourier transform (FFT) is an algorithm for transforming data in the time domain to
the frequency domain. Most analyzers have an FFT processor, which performs this
transformation automatically and then stores the computed spectra into memory.
We cannot transform to the frequency domain in a continuous manner. We therefore must
sample and digitize the time domain input. The number of samples determines the resolution
(number of lines) of frequency.
Most analyzers offer resolutions of 100,200,400,800,1600,3200 or even 6400 Lines.
FFT Spectrum Analyzers take a time varying input signal, like you would see on an
oscilloscope trace, and compute its frequency spectrum.
Fourier's theorem states that any waveform in the time domain can be represented by the
weighted sum of sines and cosines. The FFT spectrum analyzer samples the input signal,
computes the magnitude of its sine and cosine components, and displays the spectrum of
these measured frequency components.
Many of these measurements were once done using analog spectrum analyzers. In simple
terms, an analog filter was used to isolate frequencies of interest. The signal power, which
passed through the filter, was measured to determine the signal strength in certain frequency
bands. By tuning the filters and repeating the measurements, a spectrum could be obtained.
No. Of Lines
No samples / 2.56
Bin resolution
Everything below 2.5 Hz (for this example) is considered to be DC. The output spectrum
thus represents the frequency range from DC to 1000 Hz with points every 2.5 Hz.
24
Frequency Spans
Before we continue, let's clarify a couple of points about our frequency span. We just
described how we arrived at a DC to 1000 Hz frequency span using a 400 mS time record.
Because the signal passes through an anti-aliasing filter at the input, the entire frequency
span is not useable. A typical filter has a flat response from DC to 1000 Hz and then rolls off
steeply from 1000 Hz to 2.56 kHz. The range between 1000 Hz and 2.56 kHz is therefore not
useable and the actual displayed frequency span stops at 1000 Hz. There is also a
frequency bin labeled 0 Hz (or DC). This bin actually covers the range from 0 Hz to 2.5 Hz
(the lowest measurable frequency) and contains the signal components whose period is
longer than the time record (not only DC). So our final displayed spectrum contains 400
frequency bins. The first covers 0 - 2.5 Hz, the second 2.5 - 5 Hz, and the 400th covers
997.5 - 1000 Hz.
The length of the time record determines the frequency span and resolution of our spectrum.
What happens if we make the time record 800 mS or twice as long? Well, we ought to get
2048 time points (sampling at 2560 Hz) yielding a spectrum from DC to 1000 Hz with 1.25 Hz
resolution containing 800 points. But the analyzer places some limitations on this. One is
memory. If we keep increasing the time record, then we would need to store more and more
points. (0.00125 Hz resolution would require 2,048,000 values.) Another limitation is
processing time. The more points you take, the longer the processing time.
Measurement Basics
An FFT spectrum is a complex quantity, This is because each frequency component has a
phase relative to the start of the time record. (Alternately, you may wish to think of the input
signal being composed of sines and cosines.) If there is no triggering, then the phase is
random and we generally look at the magnitude of the spectrum. If we use a synchronous
trigger then each frequency component has a well-defined phase.
Spectrum
The spectrum is the basic measurement of an FFT analyzer. It is simply the complex FFT.
Normally, the magnitude of the spectrum is displayed. The magnitude is the square root of
the FFT times its complex conjugate. (Square root of the sum of the real (sine) part squared
and the imaginary (cosine) part squared). The magnitude is a real quantity and represents
the total signal amplitude in each frequency bin, independent of phase.
If there is phase information in the spectrum, i.e. the time record is triggered in phase with
some component of the signal, then the real (cosine) or imaginary (sine) part or the phase
may be displayed. The phase is simply the arc tangent of the ratio of the imaginary and real
parts of each frequency component. For vibration measurements phase is usually
considered to be relative to the trigger pulse.
25
Parameter Selection
Selecting displacement, velocity or acceleration
As previously discussed, displacement amplitude is higher at lower frequencies. Therefore
when motions are being measured a displacement measurement is in order because
frequencies of interest on the shaft are limited to 20 or so orders of rotation. For a 3600 rpm
machine, 20 orders is a frequency of 1200 Hz. At that frequency 0.5 in/sec is 0.13 mils pkpk, very small but certainly a measurable value.
For higher frequencies however, significant vibration has a displacement value which -is too
small to conveniently measure and velocity or acceleration is more appropriate. Velocity
measurements are especially good for a number of reasons.
The most prominent advantage of a velocity measurement is that the value of rms velocity is
related to the potential for mechanical damage, regardless of the frequency. The many
published vibration severity charts are based on this principle. As an example suppose a
displacement of 0.l mils is observed, is this severe? At 6 Hz this is not severe at all; at 60
Hz this is rough but at 200 Hz this is very rough and should not be permitted for machines up
to the 100HP class. Now suppose a velocity of 0.6 in/sec (15mm/s) is observed. Is this
severe? The answer is Yes, this is severe regardless of the frequency.
Newtons second law (F=ma) tells us that the acceleration of a body is directly proportional to
the force applied to the body. In other words the acceleration vibration gives a good
indication of impactive forces inside the machine such as bad bearings.
In summary, displacement measurements are good from 0 Hz to 500 Hz, velocity up to 1
kHz and acceleration from 2 Hz to 20 kHz depending on the design of the accelerometer. In
applying this to rotating machinery displacement measurements are relative readings of the
displacement of the shaft to a reference, usually the bearing. Velocity and acceleration
measurements are usually made on the bearing cap or on the machine casing in way of a
structural web to enhance the transmission of vibration to the pick-up point.
F=mx a
where F = the force
26
F=m2r
where
As we know that the acceleration is proportional to the force and we assume that the mass
and radius of force of the machine stay constant, then we may safely say that the
acceleration is also proportional to the square of the speed.
a=
2 r
The important point here is that the faster the machine goes, or the higher up the frequency
range we go, the acceleration amplitudes must increase for a given force even if there is
nothing wrong with our machine. However, we know that acceleration is simply the rate of
change of velocity. So if we integrate our acceleration reading with respect to time we will
get a velocity reading. Integrating acceleration will change our value from:
inches/second2
to
inches/second
effectively finding the square root of the acceleration (for time). We have already said that
we have a concern that the acceleration increases with frequency, so if we need a value that
is independent of frequency for severity analysis purposes we can use the velocity reading.
Back to our motor. If we plot the acceleration against time (time domain) we would see a
sine wave which is the result of simple harmonic motion. This is the signal that is passed
along to the analyzer. The analyzer will then convert this time domain signal into a
frequency domain signal either as acceleration or as an integration from acceleration into
velocity. Either way, the out of balance condition will show itself in the frequency domain as
a single spike at a frequency which corresponds to the run speed of the machine. For
example, if the motor is running at 1,200 rev/min the spike will have a frequency at 1,200
cycles/minute (cpm) or 20 Hertz (Hz).
27
Accelerometers
28
29
30
31
32
33
34
35
36
Rotor Vibration
Imbalance
Let us consider a fan impeller of 50 kg weight which is running at 1000 rpm. Let us imagine
that this impeller has an out of balance corresponding to 0.5 kg at 0.3 meter from the center
(we will use S.I. units here to make the math easier).
Newton says that:
F = (m 2 r)/9.81
using S.I. units
F is force in kg.F
m is the mass in kg
is the rotational speed in radians per second
and
1
2
37
38
39
40
41
Misalignment
42
43
44
Looseness
45
46
47
48
49
Gear Drives
A variety of gear problems can be detected by vibration analysis. These
include each of the following:
Gear Misalignment
50
3.
4.
In general, spur gears are best evaluated in radial directions, but can
sometimes have significant axial vibration as well, particularly if there is a
problem with tooth alignment. At times very high frequency
measurements will have to be made to evaluate gear condition. One
should always evaluate frequencies at least up to 2X gear mesh
frequency, but also should measure up beyond 3X gear mesh frequency
from time to time if possible (for regular PdM surveys, use an FMAX >= 4
GMF).
The author has often been involved on machines where little vibration was
occurring at the fundamental gear mesh frequency (GMF), but where much
higher vibration on the order of 10X those at the fundamental were occurring
at either 2X gear mesh or 3X gear mesh frequency (2GMF or 3GMF).
Therefore, potentially significant problems would have been overlooked had
measurements not been made up in these frequency regions.
5.
6.
7.
For a given mesh of gears, the gear mesh frequency will always be the
same no matter whether only 2, or up to 5 or 6 gears happen to be in a
common mesh. For example, in many of today's centrifugal air
compressors, there is one bull gear which meshes with each of 4 pinions
that are mounted on the first through fourth stage impellers. in this case of
5 meshing gears, there is only one gear mesh frequency.
8.
Of course, the gear mesh frequency is different for each different mesh of
gears. For example, one shaft may have one gear In a mesh on one end
and another gear on its opposite end meshing with other gears. Each of
these meshes will have individual gear mesh frequencies.
9.
51
The key indicator of gear tooth wear is not the gear mesh frequency, but
instead the gear natural frequency. In reality, there is of course more than
one gear natural frequency including separate ones for the driver and
driven gears as well as a set of those when the gears are meshing with
one another. Like everything else in nature, when a member is impacted,
it will respond at its natural frequency. In the case of gears, their natural
frequencies respond each time a defective tooth hits or impacts as it goes
into and out of mesh. The key here is that these natural frequencies will
be modulated by the impact repetition rate which will correspond to the
speed of the worn gear.
2.
Not only will sidebands appear about the gear natural frequencies, but
also about the gear mesh frequency. In the case of those around the gear
mesh frequencies, the amplitude of the sidebands themselves is a better
wear Indicator than the amplitude of GMF frequencies.
3.
4.
If more than one gear in a mesh has worn teeth., sidebands will be
established at each of the speeds of the gears having worn teeth.
52
Both eccentricity and backlash excite the gear natural frequencies as well
as gear mesh frequency. They also may generate a number of sidebands
about both the natural and gear mesh frequencies.
2.
If a gear is eccentric, it will modulate the natural frequency and gear mesh
frequencies. both of which will be sidebanded at 1X RPM of the eccentric
gear. An eccentric gear can generate significant forces. stresses and
vibration if it is forced to bottom out with the meshing gears.
53
Gear Misalignment:
The figure below is indicative of misaligned gears which almost always
excites higher order gear mesh frequency harmonics. Often, only a small
amplitude will be at the fundamental gear mesh frequency (GMF), but much
higher levels will be at 2X and/or 3X GMF. Often, the sideband spacing about
GMF frequencies might be 2X RPM, or even 3X RPM when gear
misalignment problems are involved.
54
The actual formula for this hunting tooth frequency is given in Figure 6.11G, but is
repeated here for clarity:
where:
A gear set with this gear tooth repeat problem normally will generate a "growling"
sound from the drive. It can cause quite high vibration but since it occurs at low
frequencies predominately below 600 CPM, it is often missed. It often requires the
use of a seismic accelerometer to even detect its presence. However, left
uncorrected, it can be quite destructive to gear teeth.
55
56
57
Surging
Surging is a rather common problem encountered on high speed centrifugal and axial flow
compressors and occurs when the compressor is operated outside designed limits. Typically
a compressor is designed to deliver air or other gases over a specified mass flow range and
at a specified pressure ratio. These requirements are met by selecting rotor speed, number
of compressor stages, blade configurations and other factors. The manufacturer of the
58
59
Bearing Failures
Arguably the most common type of failure on fans and fan drivers are failures arising from
the collapse of the bearings.
The vast majority of fans and fan drivers are fitted with rolling element bearings. The rolling
element bearings are usually a cylindrical rolling element bearing at the sheave end of the
motor and a ball bearing at the non-drive end. Smaller motors may have two ball bearings.
The fan may have cylindrical roller or ball bearings.
Stage 1
Lubrication problems
Stage 2
Stage 3
Stage 4
60
Ultra sonic - above the human audible range. Set at above 20 kHz for industrial applications.
61
62
63
64
= FTF
= BPFO
= BPFI
= BSF
= RPM
or
RPM * O.4* n
RPM * O.6 * n
where
BD
PD
= pitch diameter
= contact angle
When bearing geometry is not known but the number of balls or rollers can be counted or
estimated, it is suggested that the approximate equations be used to establish the bearing
frequencies of interest. All the equations listed above show a direct dependence of the
calculated frequency on the frequency of rotation.. The following figure illustrates the
bearing geometry used in the above equations
65
66
True peak is defined as the peak seen in the waveform - not the derived peak seen in the frequency
spectrum.
67
68
0.872
69
1.000
1.000
Time Waveform mS
160
2.500
2.500
0
Time Waveform mS
160
70
0.0463
71
1/4
72
73
Thin film of
silicone grease
Steel stud
Max temp 1000C (1800F)
Thin film of
silicone grease
Mica washer
Steel stud
Max temp 250C (482F)
Thin layer of
bees wax
Methyl cyanoacrylate
cement (super glue)
Methyl cyanoacrylate
cement (super glue)
soft glue
Steel stud
74
Sensitivity Deviation
H a n d
P ro b e
+
+
+
+
4
3
2
1
D u a l R a il
M a g n e t
F la t
M a g n e t
M o u n t in g
P a d
A d h e s iv e
M o u n t
S tu d
M o u n t
0
0
0
0
0
-1 0
-2 0
1 .0
1 0
1 0 0
L o g
1 0 0 0
F re q u e n c y
1 0
0 0 0
1 0 0
0 0 0
(H z )
75
Velocity
Time
Waveform
High
Frequency
Acceleration
Demodulated
Acceleration
Units
Inches/second
Gs
acceleration
Gs
acceleration
Gs
acceleration
Bandwidth
3
shaft
revolutions
RBPF x 3 @
full
speed
(f.s.)
BPFI x 8 @ f.s.
Frequency
Time
Frequency
Frequency
2048
2048
lines)
2048
lines)
Trigger
Yes if variable
spd
No
Yes if variable
spd
Window
Hanning
Rectangular
Hanning
Hanning
Averages
or BPFI x 8 @ f.s.
Domain
No.
samples
of
(800
(800
For the positioning of accelerometers the settings on the following page should be used as a
guide line.
76
Outboard
Inboard
Enveloped Acceleration (demodulation)
Velocity
Acceleration (High Frequency)
Time Waveform
Radial
Axial
Vertical AND Horizontal readings
O/B V
Group 3
Group 4
V+H
O/B
G
I/B E
I/B V
Group 5
Group 6
Group 7
V+H
I/B T
I/B A
BPFI x 8
Velocity
BPFI x 8
Acceleration G
Time waveform
3 shaft revolutions
Note: The measurements marked are for OFF-LINE systems. On-line systems require
fewer permanently mounted accelerometers but the positions noted above would still need to
be checked prior to issuing a work order based on vibration analysis.
The measurements marked are for ON-LINE systems with permanently mounted
accelerometers.
77
Measurement Windows
Many people get confused with this topic. What is windowing? Let's go back to the time
record. What happens if a signal is not exactly periodic within the time record? We said that
its amplitude is divided into multiple adjacent frequency bins. This is true but it's actually a
bit worse than that. If the time record does not start and stop with the same data value, the
signal can actually smear across the entire spectrum. This smearing will also change wildly
between records because the amount of mismatch between the starting value and ending
value changes with each record.
If a sine wave is passing through zero at the beginning and end of the time series, the
resulting FFT spectrum will consist of a single line with the correct amplitude and at the
correct frequency. If, on the other hand, the signal level is not at zero at one or both ends of
the time series record, truncation of the waveform will occur, resulting in a discontinuity in the
sampled signal. This discontinuity causes problems with the FFT process, and the result is a
smearing of the spectrum from a single line into adjacent lines. This is called "leakage";
energy in the signal "leaks" from its proper location into the adjacent lines.
Leakage could be avoided if the time series zero crossings were synchronized with the
sampling times, but this is impossible to achieve in practice. The shape of the "leaky"
spectrum depends on the amount of signal truncation, and is generally unpredictable for real
signals.
In order to reduce the effect of leakage, it is necessary that the signal level is forced zero at
the beginning and end of the time series. This is done by multiplying the data samples by a
"smoothing window" function, which can have several different shapes. The difference
between each smoothing window is the way in which they transition from the low weights
near the edges to the higher weights near the middle of the sequence. If there is no
windowing function used, this is called "Rectangular", "Flat", or "Uniform" windowing.
While the smoothing window does a good job of forcing the ends to zero, it also adds
distortion to the time series which results in sidebands in the spectrum. These sidebands, or
side lobes, effectively reduce the frequency resolution of the analyzer; it is as if the spectral
lines are wider. The measured amplitude of the weighted signal is also incorrect because a
portion of the signal level is removed by the weighting process. To make up for this
reduction in power, windowing algorithms give extra weight to the values near the middle of
the sequence.
Windows are functions defined across the time record which are periodic in the time record.
They start and stop at zero and are smooth functions in between. When the time record is
windowed, its points are multiplied by the window function, time bin by time bin, and the
resulting time record is by definition periodic. It may not be identical from record to record,
but it will be periodic (zero at each end).
In the frequency domain, a window acts like a filter. The amplitude of each frequency bin is
determined by centering this filter on each bin and measuring how much of the signal falls
within the filter. If the filter is narrow, then only frequencies near the bin will contribute to the
bin. A narrow filter is called a selective window - it selects a small range of frequencies
around each bin. However, since the filter is narrow, it falls off from center rapidly. This
means that even frequencies close to the bin may be attenuated somewhat. If the filter is
wide, then frequencies far from the bin will contribute to the bin amplitude but those close by
will not be attenuated significantly.
The net result of windowing is to reduce the amount of smearing in the spectrum from signals
not exactly periodic with the time record. The different types of windows trade off selectivity,
amplitude accuracy, and noise floor.
Several types of window functions are available including Uniform (none), Flattop, Hanning,
Blackman-Harris, and Kaiser.
78
Uniform
The uniform window is actually no window at all. The time record is used with no weighting.
A signal will appear as narrow as a single bin if its frequency is exactly equal to a frequency
bin. (It is exactly periodic within the time record). If its frequency is between bins, it will affect
every bin of the spectrum. These two cases also have a great deal of amplitude variation
between them (up to 4 dB).
In general, this window is only useful when looking at transients which do not fill the entire
time record.
Hanning
The Hanning window is the most commonly used window. It has an amplitude variation of
about 1.5 dB (for signals between bins) and provides reasonable selectivity. Its filter roll off
is not particularly steep. As a result, the Hanning window can limit the performance of the
analyzer when looking at signals close together in frequency and very different in amplitude.
Flattop
The Flattop window improves on the amplitude accuracy of the Hanning window. Its
between-bin amplitude variation is about 0.02 dB. However, the selectivity is a little worse.
Unlike the Hanning, the Flattop window has a wide pass band and very steep rolloff on either
side. Thus, signals appear wide but do not leak across the whole spectrum.
Blackman-Harris
The Blackman-Harris window is a very good window to use with the spectrum analyzer. It
has better amplitude accuracy (about 0.7 dB) than the Hanning, very good selectivity and the
fastest filter rolloff. The filter is steep and narrow and reaches a lower attenuation than the
other windows. This allows signals close together in frequency to be distinguished, even
when their amplitudes are very different.
Kaiser
The Kaiser window, which is available on IRD analyzers, combines excellent selectivity and
reasonable accuracy (about 0.8 dB for signals between exact bins). The Kaiser window has
the lowest side-lobes and the least broadening for non-bin frequencies. Because of these
properties, it is the best window to use for measurements requiring a large dynamic range.
79
Averaging
In general, averaging many spectra together improves the accuracy and repeatability of
measurements.
RMS Averaging
RMS averaging computes the weighted mean of the sum of the squared magnitudes (FFT
times its complex conjugate). The weighting is either linear or exponential.
RMS averaging reduces fluctuations in the data but does not reduce the actual noise floor.
With a sufficient number of averages, a very good approximation of the actual random noise
floor can be displayed.
Since RMS averaging involves magnitudes only, displaying the real or imaginary part or
phase of an RMS average has no meaning. The RMS average has no phase information.
Peak Hold
Peak Hold is not really averaging, instead, the new spectral magnitudes are compared to the
previous data, and if the new data is larger, then the new data is stored. This is done on a
frequency bin by bin basis. The resulting display shows the peak magnitudes which occurred
in the previous group of spectra.
Peak Hold detects the peaks in the spectral magnitudes and only applies to Spectrum, PSD,
and Octave Analysis measurements. However, the peak magnitude values are stored in the
original complex form. If the real or imaginary part or phase is being displayed for spectrum
measurements, the display shows the real or imaginary part or phase of the complex peak
value.
Linear Averaging
Linear averaging combines N (number of averages) spectra with equal weighting in either
RMS, Vector or Peak Hold fashion. This type of averaging is useful for eliminating
transients.
Exponential Averaging
Exponential averaging weights new data more than old data.
according to the formula,
80
81
Overlap Percentage
The amount of overlap is specified as a percentage of the time record. 0% is no overlap and
99.8% is the typical maximum. The maximum overlap is determined by the amount of time
it takes to calculate an FFT and the length of the time record and thus varies according to the
span. For vibration analysis of rotating machinery a good overlap is 50% as this ensures that
no data is zeroed out by the smoothing windows, yet sufficient samples are gathered for a
valid analysis.
82
Analysis
The following procedure gives an overview of the procedure to take in the
analysis of vibration frequency spectra.
Activities:
1)
Select the first plot of the machine which will be at the driver outboard and will be an
enveloped acceleration reading. Identify the run speed accurately. If you have
frequency information for the machine ensure that the reference speed is accurate if not you must change the speed reference before continuing.
2)
In the envelope spectrum see if any of the generated frequencies coincide with (or
are close to) any significant spikes. Remember that the bearing frequencies may not
be completely accurate if the bearing which has been nominated in the frequency
setup has been replaced with an equivalent.
As a rule of thumb:
Cage Frequency
3)
Once a spike at a bearing frequency has been identified you should check the
baseline for this type of machine for the trend. If the trend is deteriorating then
further checks are necessary. Be careful that you do not confuse a run speed
harmonic or an electrical frequency with a bearing defect frequency. One common
bearing frequency is just over 3 x run speed for BPOR on a 8 element bearing. The
run speed of an electric motor cannot exceed the electrical speed so harmonics of
run speed cannot have a frequency even slightly more than 3600 cpm (for a 1200
rpm motor) or 5400 cpm (for a 1800 rpm motor) or 10,800 cpm (for a 3600 rpm
motor) - if the spike is even at a slightly higher frequency then it is likely caused by a
bearing defect otherwise it is likely a run speed harmonic or an electrical frequency.
Check the time domain signal for angel fish patterns.
4)
In the single spectrum plot double click on the convert the display to dB(G)
(referenced to 0.001 G). Identify the carpet amplitude in dB(G) - this is the average
amplitude (excluding spikes). Identify the amplitude of the spikes above the carpet
level. The following rules of thumb apply to enveloped acceleration levels in dB(G):
5)
under lubrication
minor marking
marked race.
If the spectrum shows multiples of run speed then there is an impact every rev of the
rotor, with possible looseness if there are many multiples. If the bearing defect
frequencies have sidebands of cage frequency then there is a FALSE BRINELLING
83
Move to the velocity spectrum for the same point but with amplitude set to linear.
Check to see if there are any spikes in velocity at the bearing defect, harmonics of
the defect and/or sidebands of the defect - look particularly for the third and fifth
harmonics. If any spike at these frequencies exist then there is physical spalling of
the race. If the amplitude of the spike reaches 1 mm/s then the spalling is severe.
7)
In the velocity spectrum the following patterns indicate the associated defects:
Dominant
Frequency
Secondar
y
Frequenc
y
Harmonic
s of
Dominant
Frequency
Sidebands
Dominant
Direction
Defect
Suggested
Maximum
Amplitude
@
Dominant
Frequency
1x
Nil
Nil
Nil
Radial
Imbalance
6 mm/s
1x
1/2 or 1/3
x
Multiple
Nil
Radial
Looseness
3 mm/s
1x
3x
2 or 3
Nil
Axial
Misalignmen
t
4 mm/s
BPFO / BPFI
1x
Multiple
1x / Cage
Radial
Bearings
0.5 mm/s
7,200 cpm
Rotor Bar
2 or 3
2xLF of
RBF
Any
Electrical
5 mm/s
Any
Any
Nil
Nil
Any
Resonance
7 mm/s
Gear Mesh
1x
3 or 4
1x
Radial
Gearing
1 mm/s
2x Belt
1x
2 or 3
N/A
Radial
Belts
5 mm/s
84
Severity charts
85
Page
PART 1 - GENERAL
1.01 ---------------------------------------------------------------------------------------------------------- Summary
88
1.02 ---------------------------------------------------------------------------------------------------------References
88
88
88
PART 2 - PRODUCTS
2.01 -----------------------------------------------------------------------------------------------Vibration Isolators
88
89
PART 3 - EXECUTION
3.01 -------------------------------------------------------------------------------------------------------- Installation
90
90
91
93
94
86
87
SUMMARY
Section includes types of vibration isolators required for different systems, and
establishes maximum acceptable limits for vibration of machines with five
horsepower or greater, in terms of:
1.02
A.
B.
C.
REFERENCES
American National Standards Institute (ANSI)
S2.2-1959 (R1990)
1.03
1.04
SUBMITTALS
A.
B.
QUALITY ASSURANCE
Contractor is required to demonstrate to Sandia that equipment complies with
requirements of this specification. Measurements can be taken elsewhere, and
documents submitted as evidence of passage; but final acceptance judgement shall
be made from measurements taken on site in equipments final, installed location
and operating configuration. Equipment shall not be accepted until fully compliant
with specified requirements.
PART 2 - PRODUCTS
2.01
VIBRATION ISOLATORS
Spring and Resilient Pad Hangars: Stable steel spring and neoprene isolator placed
in series, and encased in welded steel bracket, with allowance for rod misalignment
up to 15 degrees without short-circuiting. Provide Mason Industries, Inc., Model
PC30N, or approved equal.
88
2.02
General
1. Capable of filtered displacement readings at rotational speed.
a. Provide separate speed-measuring device, such as strobe light, photo
tachometer, or mechanical tachometer, to measure rotating speed of
belt-driven or variable-speed machines.
b. Displacement Readings: Mils (0.001 inch), peak-to-peak.
c. Filter Bandwidth: Sufficiently narrow to achieve accuracy of 10
percent from absolute value.
2. Velocity Measurement: Overall in 10 to 1,000 Hz bandwidth, readings in
inches per second, peak.
3. Acceleration Measurement: Overall in 0 to 5,000 Hz bandwidth, readings
in g, peak.
a. Capability to record and plot waveform with 100-microsecond
resolution (5,000-Hz frequency span and 500 lines with Fast Fourier
Transform (FFT) analyzer).
b. Record and plot waveform for acceleration level failures to aid
analysis.
4. FFT analyzer with accelerometer can meet the above requirements.
B.
C.
D.
89
PART 3 - EXECUTION
3.01
INSTALLATION
A.
Piping Systems: Connect refrigerant piping to compressors with refrigerantrated, flexible metallic sections, oriented parallel to crankshaft.
1. Use flexible connections parallel to crankshaft to connect building air
piping to air compressors.
2. When piping vibration hangars are specified, provide spring hanger
isolators as described in Part 2.
B.
Ductwork:
Attach to fans with weatherproof, flame-retardant flexible
connections.
When duct vibration hangars are specified, provide spring hanger isolators
described in Part 2.
3.02
VIBRATION TESTING
A.
B.
C.
D.
E.
F.
90
H.
3.03
VIBRATION LIMITS
A.
91
Overall Velocity
Balance Condition
Overall
Acceleration
Displacement
(in/sec, Peak
10 - 1,000 Hz)
2.0
0.2
0.5
1.0
0.2
1.0
2.0
0.2
0.5
4.0
0.3
0.5
600-1,000 rpm
3.0
0.3
1.0
1,000-2,000 rpm
2.0
0.3
1.5
2.0
(g, Peak
0 - 5,000 Hz)
Electric Motors
Generators
Centrifugal Fans
1.0
0.3
Vaneaxial Fans
1.0
0.2
0.5
Blowers
1.0
0.3
0.5
2.0
0.2
0.5
Pumps
1800 rpm
1.0
0.2
1.0
Centrifugal Compressors
3600 rpm
1.0
0.2
3.0
3.0
0.4
2.0
Reciprocating Engines
5.0
1.0
10.0
Turbines
1.0
0.2
0.5
Gearboxes
1.0
0.4
2.0
1.0
1.0
15.0
Gas or Diesel
B.
Displacement Ratio =
1
((MB/M) + 1)
where:
MB
C.
D.
92
3.04
B.
Vibration Spectrum Plots: Include with written report minimum of plots for
each machine (in velocity units); one plot for driver machine and another for
driven machine.
For machines that pass, choice of which point to plot is at discretion of
analyst. Plots are intended to serve as evidence of passing, and as
baseline data for future analysis.
93
Equipment
Location
Balance
Displacement
(mil, P-P)
Overall Velocity
(in/sec Peak
10-10,000 Hz)
Overall
Acceleration
(g, Peak
0 - 5,000 Hz)
MAU-1
Horizontal
1.2
0.09
0.8
Vertical
0.9
0.12
0.7
Axial
0.4
0.08
0.8
Drive End
Horizontal
1.1
0.13
0.9
Bearing
Vertical
0.8
0.15
1.0
1,200 rpm
Axial
0.6
0.10
0.9
Horizontal
0.9
0.10
0.2
1,770 rpm
Vertical
0.7
0.12
0.3
Axial
0.5
0.09
0.1
Opposite
Horizontal
1.0
0.09
0.2
Drive End
Vertical
0.8
0.11
0.15
1,770 rpm
Axial
0.2
0.09
0.11
Pass
or
Fail
Pass
1,200 rpm
3.05
RESONANCE
A.
B.
94
Pass
Setup
Interval
Analysis
Parameter
Technology
External Manifestation
Failure Type
Base Cause
Let us take each of these components and look at them in detail from the roots up.
Base cause
As the name suggests this is the root cause of any potential failure. Examples could be:
lubrication problems, misalignment, manufacturing defects and so on. The base cause often
branches out to more than one failure type, for example misalignment could cause a bearing
failure or a shaft breakage.
Failure type
This is the failure that we could expect from the base cause. In other words this is a very
short description of the actual failure that the machine would suffer should the base cause
carry on without remedial work being carried out.
External manifestation
This is where we start getting technical. How will the problem show itself at the various
stages of failure? For illustration we will discuss the four stages of bearing failures and how
they show themselves. An example would be that a misalignment would show itself as an
increase in vibration at the machine, whereas a plugged heat exchanger would show itself as
a rise in differential pressure and with a change in temperature from optimum of the cooled
fluid.
95
Technology
So now we know how the problem will show its ugly head but what is the best technology to
detect it. We have already said that misalignment shows itself as a rise in vibration so the
technology to use would be a vibration based technology. The heat exchanger temperature
change may be detected by a mercury-in-glass thermometer or alternatively by the use of
infra-red technology. At this stage you need to have detailed understanding of the failure
modes and predictive maintenance applications.
Parameter
So the technology of choice for detection misalignment is vibration, but what type of vibration
is best? In this case the best vibration parameter is velocity. For the heat exchanger we
may decide that the most suitable parameter is a radiometric thermal image or maybe we will
decide to use a simple point and shoot infra-red thermometer.
Analysis
At this point we are giving the analyst an idea of what detail he should expect to see in the
chosen parameter when the subject machine has a developing defect. Our misalignment will
show as an increase in velocity vibration in the axial direction for a belt driven machine at run
speed with two or three harmonics and our thermal image will show a high temperature
gradient across the cooler.
Interval
How often do we need to take the reading to ensure that we do not miss a developing
problem. For example if we are looking for rolling element bearing defects we should take
the readings at least once a month but if we are looking for a misalignment then once every
three months would be ample.
Setup
To detect the misalignment we have said that we will use vibration technology with a velocity
parameter and that we are looking for two or three multiples of run speed in the frequency
spectrum. If that is the only defect that we are looking for then we can safely set the
maximum frequency in the spectrum at about ten time run speed with 400 lines of resolution
as we are not looking for small changes in frequency such as slip sidebands.
96
97
Consider figure 1, above. It shows the four stages of a rolling element bearing failure.
Before you can develop the PFA tree for the rolling element bearing you must have a
thorough understanding of the possible failure modes and extrapolate these modes to their
logical conclusions.
Stage 1
Notice that the first stage of the defect is linked to lubrication problems. At this stage we can
detect any problems using high frequency vibration parameters such as demodulation or ultra
sonics. To detect a defect at this stage with vibration we need to use a high frequency
technique such as envelope signal processing (ESP) with the following parameters:
Fmax
Envelope filter = 2.5 - 5 kHz (for electric motor bearings up to about 250 HP)
No lines
Window
Averages
= 400 or 800
= Hanning, Hamming or Kaiser
= typically 4 with maybe 50% overlap
If your data collector does not support a high frequency function such as ESP or HFB then
take an overall acceleration reading.
Stage 2
The next stage of failure involves light marking of the bearing. Again the parameter of
choice is a high frequency technique but experience tells us that a spectral parameter is most
suited to detecting marked races. So the choice here would almost certainly be ESP. The
setup for the ESP reading would be the same as in stage 1. The onset of stage 2 can be also
be detected by searching for a rise in amplitude in resonance frequencies so if you do not
have ESP you can take a velocity or acceleration spectrum with an Fmax above resonance.
If we expect resonance to occur at about 2 kHz then the Fmax should be about 3 kHz. Note
that if you are using seismic velocity transducers you will not be able to look this high in the
frequency range.
Stage 3
The third stage of the bearing failure is when the bearing starts to spall. At this stage we start
to see the defect in velocity usually at the third or fifth harmonic of the bearing defect
frequency. We may also see sidebands of run speed or cage frequency around the defect
frequencies or their harmonics. We should be taking an ESP and a velocity reading. The
ESP reading should be the same as that set up in stage 1. The velocity reading should be
set up as follows:
Fmax
or
No lines
Window
Averages
= 400 or 800
= Hanning, Hamming or Kaiser
= typically 4 with maybe 50% overlap
We should also take a time waveform reading in G acceleration to look for the bearing
impacts at all stages of the failure. The time duration should be calculated to be enough to
show about 3 revs of the shaft. We also need enough resolution in the time domain to be
able to differentiate the impacts and calculate the frequencies of occurrence of the impacts.
Usually 1,024 samples is adequate resolution. To calculate the Fmax in the point setup
screen we use the following formula:
Fmax =
No. of samples
98
1024
0.0502 x 3 x 2.56
= 2,656 Hz
So we would set the Fmax to 2.5 kHz or the nearest available frequency.
Stage 4
The final stage of failure is when the bearing physically collapses. At this stage the bearing
overheats dramatically and very quickly. Temperature measurement using embedded
thermo-couples have been used successfully for protection systems but usually only for
thrust bearings which develop the raised temperature before standard radial support
bearings.
Quantify the best contemporary method for detecting the failure mechanism
Define set up parameters to best use the detection method for this failure mechanism
99
Bearing Failure
External
Manifestation
High frequency
resonance @ bearing
defect frequency intervals
Technology
Vibration
Parameter
Demodulation
(Ultra Sound)
Time
Waveform
Spalled
bearings
Bearing Failure
Harmonics of bearing
defect frequencies
Vibration
Analysis
Interval
On Line
Set Up
Fmax = BPFI x 8
Radial
G acceleration
Peaks in waveform
On Line
= 3 revs
Velocity
On Line
Fmax = BPFI x 8
(higher if not using
resonance parameter)
Radial
Time
Waveform
Peaks @ 12 G (roller)
7 G (ball brg)
On Line
= 3 revs
G acceleration
Misalignment
Bearing Failure/
Shaft Failure
Vibration
Velocity
On Line
Fmax = 10 x rpm
Axial
Looseness
Bearing Failure/
Shaft Failure/
Structural Failure
Vibration
Velocity
On Line
Fmax = 10 x rpm
Vertical
Bad S.C.R.s
Winding
defects
Rotor
defects
Vibration
Velocity
Thermography
Thermal Image
On Line
6 month
Different current /
Current Draw
input phase
Stator temp. rise/
Thermography
Uneven temp. distribution
Amps
Unbalanced supply
6 month
Thermal image
(spot temp)
6 month
1 baseline
Insulation test
Megger
6 month
Motor de-energized
Rotor failure
Line frequency +
sidebands
Motor load
Motor current
current analysis frequency
6 month
Press idling
Motor burnout
Vibration
Reduced Power
Motor Burnout
Motor burnout
Velocity
On Line
Fmax = RBPF x 3
Radial
c. Ron Frend - PreDiCon
100
Conclusion
The method outlined in this paper for setting up the type of readings in a predictive
maintenance system will result in quantifiable, repeatable and useful measurements if these
factors are taken into consideration:
The engineer or technician defining the measurements must be familiar with previous
failures encountered on machines similar to the machine under scrutiny
The engineer or technician defining the measurements must be aware of the limitations
of the technology which is used for the measurement.
Finally, dont limit yourself to only taking vibration measurements - there are a host of other
technologies out there which complement vibration in a predictive maintenance application.
INSPECTION - CCTV
(reference marks req'd)
CORROSION
FRETTING/CLEARANCE INCREASE
DRIVE ASSEMBLY
GREASE SEAL FAILURE
MATERIAL CHOICE
ROTARY SIEZURE
BEARING COLLAPSE
LOADING
MATERIALS / LOADING
DESIGN
OVER TEMPERATURE
LUBRICATION / LOADING
DESIGN
DRIVE SIEZURE
DESIGN
DESIGN
BEARING DEFECTS
BRINNELLING
LUBRICATION / CLEARANCE
DESIGN
DESIGN
DIRT/MATERIALS CHOICE
NOISE / VIBRATION
101
PROBLEMS
OVER TEMPERATURE
FORIEGN BODY INGRESS
BEARING DEFECTS
ULTRA-LOW SPEED
PARTIAL ROTATION
CORROSION
BRINNELLING
PROBLEM
RADIATION
HEAD 2
102
External
Manifestation
Technology
Parameter
Dry/Marked
bearings
Bearing Failure
High frequency
resonance @ bearing
defect frequency intervals
Vibration
Demodulation
(Ultra Sound)
Spalled
bearings
Bearing Failure
Harmonics of bearing
defect frequencies
Vibration
Velocity
Bearing Failure/
Shaft Failure/
Structural Failure
Vibration
Interval
Set Up
Fmax = BPFI x 8
Radial
G acceleration
On Line
Peaks in waveform
On Line
= 3 revs
On Line
Fmax = BPFI x 8
(higher if not using
resonance parameter)
Radial
Time
Waveform
Peaks @ 12 G (roller)
7 G (ball brg)
On Line
= 3 revs
G acceleration
Velocity
Multiples ofBPFO
or BPFI in velocity
Sect. 3.5
Time
Waveform
Looseness
Analysis
On Line
Fmax = 10 x rpm
Vertical
1 Baseline
103
Transfer Function
The transfer function is the ratio of the spectrum of channel 2 to the spectrum of channel 1.
For the transfer function to be valid, the input spectrum must have amplitude at all
frequencies over which the transfer function is to be measured.
Cross Spectrum
The cross spectrum is defined as:
cross spectrum = FFT2 conj(FFT1)
The cross spectrum is a complex quantity which contains magnitude and phase information.
The phase is the relative phase between the two channels. The magnitude is simply the
product of the magnitudes of the two spectra. Frequencies where signals are present in both
spectra will have large components in the cross spectrum.
Orbit
The orbit is simply a two dimensional display of the time record of channel 1 vs. the time
record of channel 2. The orbit display is similar to an oscilloscope displaying a "Lissajous"
figure.
Coherence
Coherence measures the percentage of power in channel 2 which is caused by (phase
coherent with) power in the input channel. Coherence is a unit-less quantity which varies
from 0 to l. If the coherence is 1, all the power of the output signal is due to the input signal.
If the coherence is 0, the input and output are completely random with respect to one
another. Coherence is related to signal to noise ratio (S/N) by the formula:
2
S/N = /(l - )
where 2 is the traditional notation for coherence.
Correlation
The two channel analyzer may also compute auto and cross correlation. Correlation is a time
domain measurement which is defined as follows:
*
104
Spectrum
Although the linear magnitude scale is used most often for displaying spectra, another way of
displaying amplitude is the Log Magnitude. The Log Mag display graphs the magnitude of
the spectrum on a logarithmic scale.
Why is the Log Mag display useful? Remember that the 16 bit analyzer has a dynamic range
of about 90 dB. below full scale. Imagine what something 0.01% of full scale would look like
on a linear scale. If we wanted it to be 1 inch high on the graph, the top of the graph would
be 833 feet above the bottom - It turns out that the log display is both easy to understand and
shows features which have very different amplitudes clearly.
The real and imaginary parts are always displayed on a linear scale. This avoids the problem
of taking the log of negative voltages.
Phase
In general, phase measurements are only used when the analyzer is triggered. The phase is
relative to the pulse of the trigger.
The phase is displayed in degrees or radians on a linear scale, usually from -180 to +180
degrees.
The phase of a particular frequency bin is set to zero in most analyzers if neither the real nor
imaginary part of the FFT is greater than 0.012% of full scale (-78 dB below f.s.). This avoids
the messy phase display associated with the noise floor. (Remember, even if a signal is
small, its phase extends over the full 360 degrees.)
Advanced functions
Representation by complex numbers
Sometimes the representation of the spectrum is carried out by the use of rotating vectors
instead of sine waves. For complex signals this is often much more convenient. Consider
the vector below.
105
a
t
0
a+b
106
Triggering
As mentioned previously a trigger may be set up on a machine to control the acquisition of
data. This trigger is often a 5 volt, once per rev pulse or it could be from an encoder giving
many pulses per rev. A many pulse per rev trigger requires an external clock input to the
collector which is programmed to the number of pulses per rev. A third type of trigger is a
single pulse or voltage change and is known as an event trigger.
Encoder trigger
The encoder will give many pulses per rev and must be input to the external clock input.
This input is necessary for torsional vibration and should ideally be used for time
synchronous averaging where the speed may be expected to change from moment to
moment.
107
Event trigger
This is probably the simplest trigger and may be setup as a channel reading or an external
trigger. The trigger level is set and the analyzer just sits there waiting for the trigger
amplitude to reach the pre-defined level. The analyzer is actually collecting data all of the
time but is only storing as much as the memory will allow. When the trigger is activated the
data storage will commence. If the trigger is set up as a pre-trigger, then some data
collected before the trigger event will be collected as well as some data after the trigger. A
post-trigger will collect data only after the event. This can be very useful if the subject
machine is suffering from a transient fault.
108
Resonance
To design a machine installation including the structure, piping, ductwork, etc., such that
there are no natural frequencies coincident with any significant exciting force generated by
the machine is, indeed, an extremely difficult task. As a result, resonance is a very common
problem throughout industry. There are many ways to confirm whether or not a part is
vibrating at resonance. Amplitude and phase versus RPM plots ('Bode' Plots) obtained
during the startup or coast down of a machine, positively identify the resonance frequencies
by the characteristic peak amplitude and 180 degrees shift in the phase of vibration. If an
instrument with a tracking filter or trigger is not available for obtaining plots of amplitude and
phase versus machine RPM, the resonance frequencies can be determined by viewing the
long time waveform during machine startup or coast down as long a speed indication is also
available.
Impact hammer
A better way of determining natural frequencies is to use the impact hammer. This is simply
a hammer with a force transducer mounted which will send a trigger signal to start collecting
data the instant the hammer hits the structure. An accelerometer is mounted on the structure
and the resultant output is generated by the natural frequencies of the structure.
109
110
111
Glossary
A
Accelerometer
Transducer for measuring vibration in the form of acceleration. It is one of
the most rugged transducers for vibration measurements and also has the
widest frequency range.
AC
Literally Alternating Current but often used to imply a time-fluctuating signal.
Acceleration
The rate of change of velocity in inches/second/second or Gs (acceleration
due to gravity is 1 G). This is a good indicator of the forces inside a machine
since F = m.a (Newtons 2nd law).
ADC
Acronym for Analog to Digital conversion
Alarm
Alarms are used to identity specific operating conditions or to define the
boundaries between safe and unsafe conditions. When an amplitude
reaches or exceeds the alarm amplitude then the software automatically
generates an exception report.
Anti Aliasing
Nyquist's theorem says that as long as the sampling rate is greater than twice
the highest frequency component of the signal, then the sampled data will
accurately represent the input signal. Certain analyzers pass the input signal
passes through an analog filter which attenuates all frequency components
above Fmax by 90 dB to make sure that Nyquist's theorem is satisfied. This
is the anti-aliasing filter.
ASCII
American Standards Code for Information Interchange.
112
Attenuation
The weakening of a signal by distance from the source or a mechanical
interface.
Averaging
In general, averaging many spectra together improves the accuracy and
repeatability of measurements.
B
Band Pass Filter
A measurement filter that removes data below the low cutoff frequency and
above the high cutoff frequency. The band pass filter only passes the data
between the cutoff frequencies.
Bin
See resolution
Blackman-Harris Window
The Blackman-Harris window is a very good window to use with the spectrum
analyzer. It has better amplitude accuracy (about 0.7 dB) than the Hanning,
very good selectivity and the fastest filter rolloff. The filter is steep and
narrow and reaches a lower attenuation than the other windows. This allows
signals close together in frequency to be distinguished, even when their
amplitudes are very different.
C
Calibration
The process of multiplying or dividing the voltage signal from a transducer by
a factor that represents a specific engineering quantity. e.g. 100 mV/G for an
accelerometer.
Coherence
Coherence measures the percentage of power in channel 2 which is caused
by (phase coherent with) power in the input channel. Coherence is a unitless
quantity which varies from 0 to l. If the coherence is 1, all the power of the
output signal is due to the input signal. If the coherence is 0, the input and
output are completely random with respect to one another. Coherence is
related to signal to noise ratio (S/N) by the formula:
Ron Frend 2006
113
D
Database
A collection of information files that are ties together by a common topic. A
database allows rapid access of the database files.
Data Collector
Hardware device for collecting vibration data off line.
114
Decibel (dB)
A convenient unit for displaying logarithmic data.
dB = 10 log (X/X)
where X or X is
a power or squared quantity
or
dB = 20 log (Y/Y)
= Displacement /(2..f)
where f = frequency
n.b. remember 1G = 386 in/s2
E
Envelope Measurements
A.k.a. demodulation (see appendix)
Exception
To have an alarm condition. Data is outside the defined safe area.
Exponential Averaging
Exponential averaging weights new data more than old data.
takes place according to the formula,
Averaging
115
Exponential averages "grow" for approximately the first 5N spectra until the
steady state values are reached. Once in steady state, further changes in the
spectra are detected only if they last sufficiently long. Make sure that the
number of averages is not so large as to eliminate the changes in the data
that might be important.
F
Flattop Window
The Flattop window improves on the amplitude accuracy of the Hanning
window. Its between-bin amplitude variation is about 0.02 dB. However, the
selectivity is a little worse. Unlike the Hanning, the Flattop window has a
wide pass band and very steep rolloff on either side. Thus, signals appear
wide but do not leak across the whole spectrum.
FFT Spectrum Analyzer
FFT Spectrum Analyzers take a time varying input signal, like you would see
on an oscilloscope trace, and compute its frequency spectrum.
Fourier or FFT
Fourier's theorem states that any waveform in the time domain can be
represented by the weighted sum of sines and cosines. The FFT spectrum
analyzer samples the input signal, computes the magnitude of its sine and
cosine components, and displays the spectrum of these measured frequency
components.
Frequency
The rate at which periodic events happen. Typical units are Hertz (Hz),
Cycles per Minute (cpm) or orders (multiples of run speed).
Fundamental Frequency
Primary frequency, such as operating speed, to which other frequencies may
be referred back.
116
H
Hanning Window
The Hanning window is the most commonly used window. It has an
amplitude variation of about 1.5 dB (for signals between bins) and provides
reasonable selectivity. Its filter rolloff is not particularly steep. As a result,
the Hanning window can limit the performance of the analyzer when looking
at signals close together in frequency and very different in amplitude.
Harmonic
Frequencies at direct multiples of a fundamental frequency. The fundamental
is not necessarily the run speed.
Hertz (Hz)
Common frequency units in cycles per second. Named after, Heinrich Rudolf
Hertz (1857-94). German physicist born in Hamburg and educated at the
University of Berlin. From 1885 to 1889 he was a professor of physics at the
technical school in Karlsruhe and after 1889 a professor of physics at the
university in Bonn. Hertz clarified and expanded the electromagnetic theory
of light that had been put forth by the British physicist James Clerk Maxwell in
1884. Hertz proved that electricity can be transmitted in electromagnetic
waves, which travel at the speed of light and which possess many other
properties of light. His experiments with these electromagnetic waves led to
the development of the wireless telegraph and the radio. The unit of
frequency that is measured in cycles per second was renamed the hertz; it is
commonly abbreviated Hz.
High Pass Filter
A measurement filter that removes data below its low cutoff frequency.
I
Input Couple
Measurements may be AC or DC coupled. Use DC coupling for process
measurements and use AC for vibration measurements. DC coupling
includes both DC and AC signals whereas AC coupling does not include any
DC offsets.
Integrate
Integration is the opposite to differentiation and changes acceleration to
velocity and velocity to displacement where A = V x (2..f)
Ron Frend 2006
117
K
Kaiser
The Kaiser window, which is available on IRD analyzers, combines excellent
selectivity and reasonable accuracy (about 0.8 dB for signals between exact
bins). The Kaiser window has the lowest side-lobes and the least broadening
for non-bin frequencies. Because of these properties, it is the best window to
use for measurements requiring a large dynamic range.
L
Leakage
Errors resulting from Fourier transforming nonperiodic time domain data.
This effect is reduced by using windows such as Hanning or Flat Top.
Linear
Linear scaling displays all data on an equal basis. Small signals may be hard
to detect with linear scaling but become visible with logarithmic scaling.
Linear Averaging
Linear averaging combines N (number of averages) spectra with equal
weighting in either RMS, Vector or Peak Hold fashion. This type of averaging
is useful for eliminating transients.
Line of Resolution
see resolution
Logarithmic
Although the linear magnitude scale is used most often for displaying spectra,
another way of displaying amplitude is the Log Magnitude. The Log Mag
display graphs the magnitude of the spectrum on a logarithmic scale using
dBEU (Engineering Units) as units.
The 16 bit analyzer has a dynamic range of about 90 dB. below full scale.
Imagine what something 0.01% of full scale would look like on a linear scale.
If we wanted it to be 1 inch high on the graph, the top of the graph would be
833 feet above the bottom - It turns out that the log display is both easy to
understand and shows features which have very different amplitudes clearly.
The real and imaginary parts are always displayed on a linear scale. This
avoids the problem of taking the log of negative voltages.
118
O
Octave Analysis
The magnitude of the normal spectrum measures the amplitudes within
equally divided frequency bins. Octave analysis computes the spectral
amplitude in logarithmic frequency bands whose widths are proportional to
their center frequencies. The bands are arranged in octaves with either 1 or
3 bands per octave (1/1 or 1/3 octave analysis). Octave analysis measures
spectral power closer to the way people perceive sound, that is, in octaves.
The center frequency of each band should be calculated according to ANSI
standard S1.11 (1986). Typically the shape of each band is a third-order
Butterworth filter whose bandwidth is either a full, 1/3, or 1/12 octave. The
full octave bands have band centers at:
Center Freq: = 1 kHz x 2n
The 1/3 octave bands have center frequencies given by:
Center Freq: = 1 kHz x 2(n-30/3)
Operating System
A form of software that controls and supervises how the computer operates.
It loads programs, handles input and output operations and accepts and
executes commands issued by the user.
Orbit
The orbit is simply a two dimensional display of the time record of channel 1
vs. the time record of channel 2. The orbit display is similar to an oscilloscope
displaying a "Lissajous" figure.
Orders
A frequency axis scale which is useful for viewing data as a function of the
operating speed. The first order corresponds to the operating speed, the
second order is two times the operating speed and so on.
Overall
A single value representing the vibration or some other measurement
parameter. For vibration measurements this value includes vibration at all
frequencies.
Overlap Processing
Ron Frend 2006
119
What about narrow spans where the time record is long compared to the
processing time which is what we normally see when taking vibration
measurements? The analyzer computes one FFT per time record and can
wait until the next time record is complete before computing the next FFT.
The update rate would be no faster than one spectra per time record. With
narrow spans, this could be quite slow.
And what is the processor doing while it waits? Nothing. With overlap
processing, the analyzer does not wait for the next complete time record
before computing the next FFT. Instead it uses data from the previous time
record as well as data from the current time record to compute the next FFT.
This speeds up the processing rate. Remember, most window functions are
zero at the start and end of the time record. Thus, the points at the ends of
the time record do not contribute much to the FFT. With overlap, these
points are re-used" and appear as middle points in other time records. This
is why overlap effectively speeds up averaging and smoothes out window
variations.
Typically, time records with 50% overlap provide almost as much noise
reduction as non-overlapping time records when RMS averaging is used.
When RMS averaging narrow spans, this can reduce the measurement time
by a factor of two.
The amount of overlap is specified as a percentage of the time record. 0% is
no overlap and 99.8% is the maximum (511 out of 512 samples re-used).
The maximum overlap is determined by the amount of time it takes to
calculate an FFT and the length of the time record and thus varies according
to the span.
P
Peak
The maximum value as seen in the time domain data. For a sine wave
peak = RMS x 1.414
Peak Hold Averaging
Peak Hold is not really averaging, instead, the new spectral magnitudes are
compared to the previous data, and if the new data is larger, then the new
data is stored. This is done on a frequency bin by bin basis. The resulting
display shows the peak magnitudes which occurred in the previous group of
spectra.
Peak Hold detects the peaks in the spectral magnitudes and only applies to
Spectrum, PSD, and Octave Analysis measurements. However, the peak
magnitude values are stored in the original complex form. If the real or
imaginary part or phase is being displayed for spectrum measurements, the
display shows the real or imaginary part or phase of the complex peak value.
120
Phase
In general, phase measurements are only used when the analyzer is
triggered. The phase is relative to the pulse of the trigger. The phase is
displayed in degrees or radians on a linear scale, usually from -180 to +180
degrees. The phase of a particular frequency bin is set to zero in most
analyzers if neither the real nor imaginary part of the FFT is greater than
about 0.012% of full scale (-78 dB below f.s.). This avoids the messy phase
display associated with the noise floor. (Remember, even if a signal is small,
its phase extends over the full 360 degrees.)
Power Spectral Density (PSD)
The PSD is simply the magnitude of the spectrum normalized to a 1 Hz
bandwidth. This measurement approximates what the spectrum would look
like if each frequency component were really a 1 Hz wide piece of the
spectrum at each frequency bin.
What good is this? When measuring broad band signals such as noise, the
amplitude of the spectrum changes with the frequency span. This is because
the line width changes so the frequency bins have a different noise
bandwidth. The PSD, on the other hand, normalizes all measurements to a 1
Hz bandwidth and the noise spectrum becomes independent of the span.
This allows measurements with different spans to be compared. If the noise
is Gaussian in nature, then the amount of noise amplitude in other
bandwidths may be approximated by scaling the PSD measurement by the
square root of the bandwidth. Thus the PSD is displayed in units of V/Hz or
dBV/Hz.
Since the PSD uses the magnitude of the spectrum, the PSD is a real
quantity. There is no real or imaginary part or phase.
R
Rayleighs Principle
This principle states that f is the lowest measurable frequency for a time
record length T:
f = 1/T
121
122
S
Sampling Rate
The original digital time record comes from discrete samples taken at the
sampling rate. The corresponding FFT yields a spectrum with discrete
frequency samples. In fact, the spectrum has less than half as many
frequency points as there are time points. Suppose that you take 1024
samples at 2560 Hz. It takes 0.4 Seconds to take this time record. The FFT
of this record yields 400 frequency points or lines, but over what frequency
range? The highest frequency will be determined by the in-built ratio of Fmax to data sampling rate - 2.56. The lowest frequency is just the F-max
divided by the number of lines:
F-max
No. Of Lines
= No samples / 2.56
Bin resolution
123
T
Tachometer
A device for measuring the speed of rotation.
Time Record
The time record measurement displays the filtered data points before the FFT
is taken For baseband spans (spans that start at DC), the time record is a
real quantity. For non-baseband spans (zooms) the heterodyning discussed
earlier transforms the time record into a complex quantity which can be
somewhat difficult to interpret.
Time Synchronous Averaging
see vector averaging
Transfer Function
The transfer function is the ratio of the spectrum of channel 2 to the spectrum
of channel 1. For the transfer function to be valid, the input spectrum must
have amplitude at all frequencies over which the transfer function is to be
measured.
Two-Channel Measurements
Two-channel analyzers offer additional measurements such as transfer
function, cross-spectrum, coherence and orbit.
U
Uniform Window
The uniform window is actually no window at all. The time record is used with
no weighting. A signal will appear as narrow as a single bin if its frequency is
exactly equal to a frequency bin. (It is exactly- periodic within the time
record). If its frequency is between bins, it will affect every bin of the
spectrum. These two cases also have a great deal of amplitude variation
between them (up to 4 dB).
In general, this window is only useful when looking at transients which do not
fill the entire time record.
124
V
Vector (Synchronous Time) Averaging
Vector averaging averages the complex FFT spectrum. (The real part is
averaged separately from the imaginary part.) This can reduce the noise floor
for random signals since they are not phase coherent from time record to time
record.
Vector averaging requires a trigger. The signal of interest must be both
periodic and phase synchronous with the trigger. Otherwise, the real and
imaginary parts of the signal will not add in phase and instead will cancel
randomly.
With vector averaging, the real and imaginary parts as well as phase displays
are correctly averaged and displayed. This is because the complex
information is preserved.
W
Windowing
What is windowing? Let's go back to the time record. What happens if a
signal is not exactly periodic within the time record? We said that its
amplitude is divided into multiple adjacent frequency bins. This is true but it's
actually a bit worse than that. If the time record does not start and stop with
the same data value, the signal can actually smear across the entire
spectrum. This smearing will also change wildly between records because
the amount of mismatch between the starting value and ending value
changes with each record.
Windows are functions defined across the time record which are periodic in
the time record. They start and stop at zero and are smooth functions in
between. When the time record is windowed, its points are multiplied by the
window function, time bin by time bin, and the resulting time record is by
definition periodic. It may not be identical from record to record, but it will be
periodic (zero at each end).
In the frequency domain, a window acts like a filter. The amplitude of each
frequency bin is determined by centering this filter on each bin and
measuring how much of the signal falls within the filter. If the filter is narrow,
then only frequencies near the bin will contribute to the bin. A narrow filter is
called a selective window - it selects a small range of frequencies around
each bin. However, since the filter is narrow, it falls off from center rapidly.
This means that even frequencies close to the bin may be attenuated
somewhat. If the filter is wide, then frequencies far from the bin will
contribute to the bin amplitude but those close by will not be attenuated
significantly.
The net result of windowing is to reduce the amount of smearing in the
spectrum from signals not exactly periodic with the time record. The different
types of windows trade off selectivity, amplitude accuracy, and noise floor.
Ron Frend 2006
125
126
Index
127
O
A
AC, 105
acceleration, 85
Analysis, 82, 83, 84
Analyzer, 104
Average, 103
Overall, 108
Overlap, 109
B
Base cause, 82
bearing, 82, 83, 85, 86
Bin, 112
Parameter, 82, 83
PFA, 82, 84, 85, 86, 87
Phase, 110
R
Resolution, 107, 111
resonance, 85
Route, 111
CPM, 101
S
D
Setup, 82, 83
Sideband, 112
spall, 85
spectrum, 83, 85
T
E
envelope, 85
Envelope, 85, 103
External manifestation, 82
Tachometer, 113
Technology, 82, 83
time, 83, 85, 86
Trigger, 72
F
Failure type, 82
FFT, 104, 109, 110, 111, 112, 113, 114
Filter, 105, 108
Fourier, 104, 107
Frequency, 104
Fundamental, 104
velocity, 83, 85
W
waveform, 85
H
Hanning, 85
Harmonic, 93, 105
Hertz, 104, 105
Hz, 20, 27, 104, 105, 110, 111, 112
I
Integrate, 105
Interval, 82, 83
K
Kaiser, 85
L
Leakage, 107
Line, 107
Logarithmic, 107
128
129
Your Company
VIBRATION STANDARD
FOR THE PURCHASE OF
NEW and REBUILT
YOUR COMPANY Specification based on Specification V1.0 is issued under the direction of the
Vibration Standards Committee.
YOUR
COMPANY-doc
130
YOUR COMPANY
VIBRATION STANDARDS
Issued by:
131
YOUR COMPANY
VIBRATION STANDARD
FOR NEW AND REBUILT MACHINERY AND EQUIPMENT
FOREWORD
Your Company requires Vibration Certification of all new and rebuilt machinery and
equipment in keeping with implementation of Synchronous Processes and Lean
Manufacturing Services. Vibration analysis and certification, as a part of machine
performance evaluation will:
132
Set First Alarm vibration levels at 2X the applicable New and Rebuilt
machine maximum acceptance levels for the machine under consideration.
This First Alarm Level would indicate the severity of the problem has
reached a stage where the developing cause of the vibration needs to be
identified, necessary repair parts identified and ordered (if not in crib
stock), date for repair established based on minimum production
interruption, and skilled trades personnel identified and scheduled for the
repair. Although the machine can continue to be run, it should be closely
monitored, particularly if it is a critical machine.
Set a Second Alarm vibration levels at 2.5X - failure pending, or 3X failure eminent. If the machine is a critical machine, it should be scheduled
for PM repairs ASAP.
The above Rules-of-Thumb are generally conservative. In time, after experience
with said machine, the vibration levels for Warning and Alarm can be adjusted to fit the
specific machine health conditions.
133
YOUR COMPANY
VIBRATION STANDARD
FOR NEW AND REBUILT MACHINERY AND EQUIPMENT
TABLE OF CONTENTS
134
135
136
TABLES
Table 1-1 VIBRATION SENSOR REQUIREMENTS 6
Table 1-2 Vibration Measurement Units 15
Table 2-1 (9.1) Isolation Pad Minumum Compression 2
Table 2-2 Critical Speed Locations 4
Table 2-3 MAXIMUM ALLOWABLE VIBRATION LEVELS FOR ELECTRIC MOTORS 5
Table 2-4 Motor Nameplate Vibration Designation 5
Table 3-1 MAXIMUM ALLOWABLE VIBRATION LEVELS FOR GEARLESS TYPE SPINDLES 3
Table 3-2 MAXIMUM ALLOWABLE VIBRATION LEVELS FOR GEARLESS TYPE SPINDLES <600
RPM 5
Table 3-3 MAXIMUM ALLOWABLE VIBRATION LEVELS FOR GEAR-DRIVEN SPINDLE
ASSEMBLIES 8
Table 4-1 MAXIMUM ALLOWABLE VIBRATION LEVELS FOR FANS 2
Table 5-1 MAXIMUM ALLOWABLE VIBRATION LEVELS FOR POSITIVE DISPLACEMENT AND
CENTRIFUGAL PUMPS 2
Table 6-1 MAXIMUM ALLOWABLE VIBRATION LEVELS FOR GEARBOXES WITH TWO (2) GEAR
SETS 5
Table 7-1 MAXIMUM ALLOWABLE VIBRATION LEVELS FOR NON-MACHINE TOOLS and NONPRECISION MACHINE TOOLS 8
Table 7-2 MAXIMUM ALLOWABLE VIBRATION LEVELS FOR PRECISION MACHINE TOOLS 10
137
FIGURES
Figure 1-1 Measurement System Frequency Response 3
Figure 1-2 Angular Convention for Foot Mounted & Flange Mounted Machines 9
Figure 1-3 Direction of Sensor Axis 9
Figure 1-4 Normal and Reverse Motion Convention Error! Bookmark not defined.
Figure 1-5 Order and Consecutive Numbering Sequence 11
Figure 1-6 Order and Consecutive Numbering Sequence 11
Figure 1-7 Vibration Measurement Locations 12
Figure 1-8 Vibration Measurement Locations 12
Figure 1-9 Vibration Measurement Locations 12
Figure 1-10 Vibration Measurement Locations 13
Figure 1-11 Frequency Bands 16
Figure 1-12 Balance Test Key Dimensions 19
Figure 1-13 Resonance Separation Margin (SM) 20
Figure 2-1 Maximum Allowable Vibration Limits for Electric Motors 7
Figure 3-1 Measurement Locations for Single Precision Spindle 1
Figure 3-2 Measurement Locations for Spindle Cluster 2
Figure 3-3 Measurement Locations for Multi-Spindle Gear-type Head 2
Figure 3-4 Line Amplitude Acceptance Limits for Gearless Type Spindles 600 to 12,000 RPM 3
Figure 3-5 Band-Limited Overall Amplitude Acceptance Limits for Gearless Type Spindles 600 to
12,000 RPM 4
Figure 3-6 Line Amplitude Acceptance Limits for Gearless Type Spindles <600 RPM 5
Figure 3-7 Band-Limited Overall Amplitude Acceptance Limits for Gearless Type Spindles <60 RPM
7
Figure 3-8 Band-Limited Overall Amplitude Acceptance Limits for Gear-Driven Spindle Assemblies 8
Figure 4-1 Line Amplitude Acceptance Limits for Fans 3
Figure 4-2 Band-Limited Overall Amplitude Acceptance Limits for Fans 3
Figure 5-1 Line Amplitude Acceptance Limits for Positive Displacement & Centrifugal Pumps 3
Figure 5-2 Band-Limited Overall Amplitude Acceptance Limits for Positive Displacement &
Centrifugal Pumps 3
Figure 6-1 Amplitude Acceptance Limits for Gearboxes 6
Figure 6-2 Band-Limited Overall Amplitude Acceptance Limits for Gearboxes 6
Figure 7-1 Line Amplitude Acceptance Limits for Non-Machine Tools and Non-Precision Machine
Tools 9
Figure 7-2 Band-Limited Overall Amplitude Acceptance Limits for Non-Machine Tools & NonPrecision Machine Tools 9
Figure 7-3 Line Amplitude Acceptance Limits for Precision Machine Tools 10
Figure 7-4 Band-Limited Overall Amplitude Acceptance Limits for Precision Machine Tools 11
138
Vibration Standard
YOUR COMPANY
VIBRATION STANDARD
FOR NEW AND REBUILT MACHINERY AND EQUIPMENT
PURPOSE
The purpose of this standard is to:
o
Improve the life and performance of rotating machines and equipment monitored by
Your Company .
o
Reduce operating costs in Your Company plants by establishing acceptable
vibration levels for new and rebuilt rotating machinery and equipment.
o
Provide a uniform procedure for evaluating the vibration characteristics of a
machine for certification and acceptance.
SCOPE
This standard establishes:
o
Acceptable limits for vibration levels generated by new and rebuilt rotating
machinery and equipment monitored by Your Company .
o
Measurement procedures -- including standardized measurement axis directions and
locations, calibration and performance requirements of instrumentation, and procedures for
reporting vibration data for machine certification and acceptance..
INSTRUMENTATION REQUIREMENTS
Vibration measurements will be made with an FFT analyzer. The type, model, serial number(s) and
latest certified calibration date of all equipment used in the measurement of vibration levels for
machine certification, shall be recorded and made available upon request.
The FFT Analyzer shall be capable of a line resolution bandwidth f = 300 CPM for
the frequency range specified for machine certification unless this restriction would
result in less than 400 lines of resolution, in which case the requirement defaults to
400 lines of resolution. (Higher resolution may be required to resolve "Side
Bands," or in Band 1 to resolve machine vibration between 0.3X and 0.8X Running
Speed.)
Software:
The computer software used to program/analyze/store machine certification
vibration data shall store the data in the Machinery Information Management Open
Systems Alliance (MIMOSA) standard data base structure, or provide full
connectivity between systems through MIMOSA compliant import/export
capability.
Calibration shall be traceable to the National Institute of Standards and Technology (NIST)
in accordance with MIL-STD-45662 "Military Standard Calibration Systems
Requirements" (10 June 1980) or latest revision.
for
converting
acceleration
3.4.6 Low and Midrange Frequency (Class 1A through Class 3A) Industrial
Accelerometers shall meet the following:
Military Connector two (2) pin per Mil Std. 5015 or equivalent performance
as applicable to the specific accelerometer.
Top mount, side mount, or integral cable connection to be determined by
user, dependent on application.
Broadband and High Frequency (Class 4A through 5A) Accelerometers shall meet
the following:
For 50 mV/g and 100 mV/g Sensitivity, must be Military Connector two (2)
pin per Mil Std. 5015 or equivalent performance as applicable to the specific
accelerometer.
For 10 mV/g Sensitivity, may use a Laboratory grade Connector
(Microdot).
Note: Accelerometers SHALL be constructed such that they direct link to a
portable data collector, and are compatible with plant equipment.
3.4.7 Other types of Vibration Sensors (such as a Laser Vibrometer) that meet or
exceed the required performances specified above and in Table 1 are acceptable for
use in meeting the requirements of this specification.
Class 1A
Class 2A
Class 3A
Class 4A
Class 5A
and
UltraLow
Frequency
Low Frequency
Mid-range
Frequency
Broad-range
Frequency
High Frequency
0.2 - 200 Hz
0.5 - 2,000Hz
10 - 5,000 Hz
10 - 10,000 Hz
10 - 25,000 Hz
0.2 - 200 Hz
0.5 - 2,000 Hz
10 - 5,000 Hz
10 - 10,000 Hz
0.5 - 2,000 Hz
10 - 2000 Hz
10 - 6,000 Hz
500 mV/g
* 50 mV/g
Frequency Type
Frequency Range
Stud Mounted, ( 5%)
Frequency Range Direct
Mounted-Adhesive ( 5%)
Frequency Range
Magnet Mounted, ( 5%)
Sensitivity ( 5%)
10,000 mV/g
* 50 mV/g
10 mV/g
or 10 mV/g
Turn-on time (sec)
5.0
0.00001
0.0002
0.0002
0.005
0.000001
Transverse Sensitivity
<3%
<5%
<5%
<5%
<5%
0.0001
0.0002
0.0008
0.0006
0.002
Industrial
Industrial
Industrial
Industrial or
May be Laboratory
Laboratory
i.e. Microdot
Strain Sensitivity
g/micro-strain
Package
(i.e. Microdot)
Shock Protect
5000g
5000g
5000g
Output Voltage
Electromagnetic
5000g
Sensitivity
Hermetic < 2 X l0 -8 cc/s of Helium @ 1 ATM.
Seal
Etching
System (e.g. PM1, Crank Line #1, Leak Test, Final Assembly, etc.) -Alpha-numeric description limited by record documentation media. (e.g. machine
layout drawing, software, etc.) Description to be agreed upon by customer and
supplier.
Machine (e.g. Drier Section, Operation 10, Landis Grinder, Mig welder,
Hydraulic Unit, etc.) -- Alpha-numeric description limited by record documentation
media. (e.g. machine layout drawing, software, etc.)
6
Station (e.g. Control Room Side, 445, Rough Bore, Underbody Weld, etc.)
-- Alpha numeric description limited by record documentation media.
Four (4)
Three (3)
Angular Orientation:
(000 to 360 degrees)
Direction of Motion:
The six convention definitions (Component Part, Location, Sensor, Angular Orientation,
Sensor Axis Orientation and Direction of Motion) SHALL be combined into a fourteen
character (no spaces) measurement identification as follows:
e.g.
SFTA003AC090RN (shaft A, bearing number 3, single axis
accelerometer positioned 90 degrees counterclockwise from zero, mounted
radially, normal motion).
This convention for specifying transducer type and angular orientation at each measurement
location IS REQUIRED for Your Company / MIMOSA compliance.
Component Part (shaft, gearbox, roll, etc.):
four (4) alphanumeric characters
Four user defined alpha numeric characters provide a flexible means to identify
specific component parts of a machine for convenience and purposes of automated
diagnosis. Examples include individual shafts rotating at different speeds within a
complete machine i.e. SFTC to indicate shaft C, an auxiliary gearbox with multiple
shaft speeds that differ from the shaft speeds of the main machine i.e., AGB6
(auxiliary gearbox, position number 6).
Reference Appendix A RECOMMENDED COMPONENT IDENTIFICATION
SYMBOLS. Since component identification utilizes only three (3) primary alpha
characters, (e.g. SFT for shaft), the fourth character space will be a null identified
by the symbol (@), alpha character such as (A), or a numerical character such as
(6).
Location (bearing number designation): three (3) numeric characters
A numeric sequence identifying the specific bearing on which a vibration
measurement is recorded using three numeric numbers. For purposes of this
Specification, the numeric sequence starts at the outboard bearing position of the
PD
Dynamic Pressure
AC
PS
Static Pressure
AT
Triaxial Accelerometer
SG
Strain Gauge
CT
Current Transformer
Thermocouple
TC
Temperature--
DP
Displacement Probe
TR
Temperature -- RTD
DR
TT
Torque Transducer
LT
TO
Torsional transducer
MP
VP
Velocity Pickup
MI
Microphone
VT
Voltage
OP
US
Ultra-Sound
AE
Acoustic Emission
OT
Other
Angular Orientation:
Position
001
Position
002
AXIAL
090
180
000
360
090
270
180
DRIVER
MACHINE
Point of
Energy Input
000
360
Position
002
Position
001
DRIVEN
MACHINE
270
Figure 0-2 Angular Convention for Foot Mounted & Flange Mounted Machines
Sensor (sensitive) Axis Direction (Orientation): one (1) letter
A single letter defines the direction of the sensor sensitive axis. This
portion of the identification provides unique descriptive information when
the sensor sensitive axis does not coincide with the radial defined in the
previous section (Reference Figure 3: XXXAC135H, XXXAC090T,
XXXAC315A). It is redundant when the sensitive axis coincides with the
defined radial (e.g. XXXAC000R and XXXAC000H).
R - Radial:
sensor sensitive axis perpendicular to and passes through the shaft axis
A - Axial:
NOTE: Axial direction (A) shall be, by definition, parallel to the rotational axis of the machine.
T - Tangential:
H - Horizontal:
V - Vertical:
Horizontal - offset
XXXAC135H
Tangential XXXAC090T
Radial Displacement
XXXDP045
Radial XXXAC225R
Axial XXXAC315A
10
009
MOTOR
001
002
003
011
012
SPINDLE #2
GEAR BOX
007
010
008
008
SPINDLE #1
004
005
006
When a machine station consists of multiple components, such as two or more spindles, consecutive
POWER FLOW
I N
&
SPL1
SPL6
SPL5
SPL3
SPL2
SPL4
SPL7
PROCESS FLOW
I N
11
00 6
005
0 04
003
002
001
D R IL L H E A D U N IT
(M U L T IP L E S P IN D L E S )
001
002
003
004
004
002
003
004
003
12
003
004
1200 RM
Motor
002
005
006
13
Deleted: or equivalent
Deleted: (6 mm).
Deleted: within 0.1 mm.
TECHNICAL REQUIREMENTS
VIBRATION MEASUREMENT UNITS
Vibration measurements and data for machine certification and acceptance shall be in the
RMS-METRIC units specified in Table 1.
NOTE: During transition from English to Metric, equivalent English values in units
specified in Table 1 may also be included in the data if enclosed by ( ).
Frequency
Rotational Speed
Revolutions
[RPS]
per
Sec
or Revolutions per
Minute [RPM]
Amplitude
METRIC
ENGLISH
Microns
Velocity
Millimeter/sec (RMS)
Inch/sec (Peak)
Acceleration
Meter/sec2
(RMS)
g's g's
or
(Peak)
15
The frequency range of measurement shall be divided into sub-groups called bands. The
Fmin and Fmax for each band will be defined in units of frequency or orders of running
speed of the machine (Ref. Figure 7).
Mandatory Bands
Band 1 shall be (0.3 - 0.8) X Running Speed [1st Order]
Band 2 shall be (0.8 - 1.2) X Running Speed [1st Order]
Band 3 shall be (1.2 - 3.5) X Running Speed [1st Order]
Other Bands
Bands 4 through N shall be defined by the specific machine tool application. Bands
4 through N may also overlap each other or be contained within each other (such as
a "Zoom" Band) as required by a specific application.
A
M
P
L
I
T
U
D
E
RPM
RPM
BAND BAND
1
2
RPM
RPM
RPM
BAND
3
BAND
4
BAND
5
RPM
BAND
Ni
2
3
4
RUNNING SPEED ORDERS
Fmax
A line of resolution will have a band width (f) = 5 Hertz (300 CPM) unless
specified otherwise (Reference Section 7.4 requirement for total energy in a peak),
16
unless the f = 5 Hertz (300 CPM) restriction would result in less than 400 lines of
resolution over the frequency range specified for certification, in which case the
resolution requirement will default to 400 lines. [Greater resolution (i.e. f < 5 Hz
(300 CPM)) may be required for low speed equipment, to resolve "Side Bands," or
in Band 1 to resolve machine vibration between 0.3X and 0.8X Running Speed.
17
A
i =1
2
i
1. 5
Ai
=
Band
(i = 1) =
(i = N) =
Hanning Window.
The transducer mounting shall be such that the measurement system amplitude accuracy
over the selected frequency range equals or exceeds the requirements specified in Section
3.2. This may require the use of more than one accelerometer where potentially high
frequencies might occur (such as gear mesh or harmonics of gear mesh) along with lower
frequencies (such as due to imbalance, misalignment, looseness, etc.).
ALIGNMENT
All coupled rotating machines consisting of consecutive shafts connected through a
coupling (whether rigid or flexible) shall be aligned within the tolerances specified by the
customer.
Consideration shall be given to any thermal growth that might occur during the normal
operation of the machine that would cause the machine to "grow out of alignment" to the
extent that the alignment tolerances of this specification would not be met.
BALANCING - Shaft and Fitment Key Convention
STANDARD KEY
For rotating machines and machine components with a keyed shaft,
this Standard requires balancing be achieved using a standard one18
half key in the key seat in accordance with ISO 8821-1989(E). ISO
8821-1989(E) applies to rotors balanced in balancing machines, in
their own housings, or in situ, and applies to keys of constant
rectangular or square cross-section, keys mounted on tapered shaft
surfaces, woodruff, gib, dowel and other special keys.
If a full key, corresponding to the half key used for balancing, is not
provided with the rotating machine, a tag, as shown in Figure 8, will
be attached to the machine indicating the dimensions of the key used
to perform the balance test.
If no key is shipped with the shaft, and a tag as shown in Figure 8 is
not attached to the shaft, the length of the half-key used originally
for balancing the shaft is assumed to be the same as the length of the
shaft keyway (Ref. ISO 8821).
The use of solder or similar deposits to achieve rotor balance is not acceptable.
Any parent metal removed to achieve dynamic or static balance shall be drilled out
in a manner which will maintain the structural integrity of the rotor.
A
B
b
a
(A X a) + (B X b)
FINAL ASSEMBLY KEY LENGTH = -----------------------a + b
FINAL ASSEMBLY KEY LENGTH = _______________
VIBRATION
LEVEL
condition of resonance might exist. Operating speeds must have a separation margin (SM)
of at least 25% of the resonance speed (o). Where multiple resonances exist, the
operating speed shall also be above or below any given resonance and removed from the
resonance by a separation margin of at least 25% of the resonance speed (Reference Figure
9).
OPERATING
SPEED
SM
SM
OPERATING
SPEED
SM
N1
SM
N2
RPM
taking place during collection of machine vibration data. Where rated load
is specified, rated operating load--either actual or simulated--will be applied
during collection of machine vibration data.
Prior to taking vibration measurements, the machine will be run-in until it
reaches speed and thermal stability.
Vibration Signatures as required by Section 9 of this specification, shall be
submitted to the customer's Maintenance Department or other authorized
representative before acceptance of the machinery or equipment being monitored
will be authorized.
Vibration data for machine certification shall be measured during run-off at the
vendor's facility. Where it is impractical to set-up and test a complete machine at
the vendor's facility, arrangements shall be made to perform the test at the
customer's facility. Under this circumstance, shipment of the equipment does not
relieve the vendor of the responsibility for meeting the specified vibration level
limits.
The customer shall have the option to verify vibration data of equipment during
machine run-off at the vendor's test site prior to shipment, or at the plant site per
Section 8.2.3, prior to final acceptance authorization.
The machine layout drawing shall be submitted as a part of the Machine Vibration
Certification. Vibration measurement locations on the machine's surface at which
vibration measurements are taken shall be designated on the drawing per Sections
4.0 and 5.0 requirements. At the option of the customer, shaft speeds, gear type
and number of gear teeth, gear mesh frequencies, bearing manufacturer's name,
bearing type number and class, shall be identified on the machine layout drawing.
Where gear boxes are involved, an insert such as illustrated in Figure 6C shall be
included on the machine layout drawing.
ACCEPTANCE
Authorization for machine/equipment acceptance based on the vibration limits of this
specification requires signature by the customer's authorized representative. A copy of the
acceptance must be sent to the plant's purchasing department before final acceptance is
authorized.
21
The Fmax shall be more than 30x the shaft run speed but
Transducer Mounting
The transducer shall be a mid-range accelerometer Class 3A
or a broad-range accelerometer Class 4A as described in Table 1, section 3.4. The
accelerometer shall be mounted using a magnet of no less than 20kg pull unless the
accelerometer is stud mounted as described in section 6.1.3.
Enveloping Filter If the transducer is magnet mounted then the enveloping
filter shall be such a frequency range that it covers the range 1kHz to 3kHz. For band-pass
filters the filter range chosen shall be the closest approximation to 1kHz 3kHz. If the
accelerometer is stud mounted, then the filter setting shall be assessed by setting the meter
to a 20kHz spectrum and impacting the machine surface near the transducer with a steel
hammer, taking care not to damage the machine surface. The area of maximum response is
the frequency range that shall be covered by the filter.
Acceptance Limits The machine shall be considered acceptable if the spectrum floor
level does not exceed 0.01 G RMS and the spectrum has no spikes at bearing defect
frequencies which are more than 5dB (re 10-6)G above the floor level.
22
9.1.1
9.1.1
2. Care must be taken that the motor does not rock on the plate
(Softfoot must be removed).
3. The linear dimensions of the plate shall not exceed those of the
projected motor base by more than 10%.
* To test motors that are to be resilient mounted upon installation, omit the steel
base plate and put the base of the motor directly on the resilient support test pad.
Resilient (Rubber or rubber like)Support Pad: - Support the motor and steel base plate on
a resilient pad per the following specifications:
Pad thickness shall be such that the downward deflection of the pad due to the static load
weight of the motor and plate will be equal to or greater than that shown in the following
table, but must in no case be more than 1/2 the original thickness of the pad.
Table 0-1 (9.1) Isolation Pad Minumum Compression
MOTOR SYNCHRONOUS SPEED
(RPM)
MILLIMETERS
(INCHES)
600
58
(2-1/4)
720
40
(1-9/16)
750
38
(1-15/32)
800
33
(1-17/64)
900
26
(1.00)
1000
21
(13/16)
1200
15
(9/16)
1500
10
(3/8)
1800
(1/4)
2400
(9/64)
3000
(3/32)
3600
(1/16)
7200
(1/64)
NOTE: The required deflection is inversely proportional to the square of the speed.
The RPMs listed in Table 9.1 is that at which the motor is run during vibration test.
For any speed not listed in Table 9.1, use the following formula:
Deflection (millimeters) = 25.4 x [900/(RPM)]2
[900/(RPM)]2
Deflection (inches) =
The resilient support pad SHALL support the entire base plate area. The
pad shall not be more than 10% larger than the base plate.
For any motor to be tested, the necessary thickness of the resilient pad can
be calculated from he following formula:
T = KDA/F
Place the proper flexible pad on the test table or horizontal surface and the proper plate on
the pad.
Place the motor squarely on the plate so that it is reasonably level [i.e. all four corners of
the base or plate are the same height above the table 4 mm ( 1/8 inch)].
Unless otherwise specified, fit the shaft keyway with half of a standard key (i.e. full length
and flush with the top of the keyway).
To avoid the possibility of bending the shaft, use a half key which is 0.005 mm (0.0002
inch) less in width than the keyway, and is held in place with tape or by other suitable means.
Large motors should be steadied during startup with a hoist sling or by other suitable
means, to avoid the danger of their being overturned.
CRITICAL SPEED
Completely assembled motors shall have a percentage separation between the rotor shaft
first actual critical speed and the rated motor speed as specified:
Table 0-2 Critical Speed Locations
FIRST ACTUAL
ROTOR DESIGN
Rigid Shaft
Flexible Shaft
Maximum of 85% of Motor Speed
LIMITS
Small (Fractional) and Medium (Integral) Horsepower AC/DC Motors:
Electrical motors defined by NEMA Standard MG-1 "Motors and Generators",
Section II Small (Fractional) and Medium (Integral) Horsepower AC/DC Machines
shall meet the following requirements:
9.1.5.1.1
The Velocity Amplitude of any line of resolution,
measured at all bearing positions in any direction radial or axial shall
not exceed the Line-Amplitude Band Limit values specified in Table
9.1A and graphed in Figure 9.1.
9.1.5.1.2
The Acceleration Overall Amplitude measured at all
bearing positions in any direction radial or axial shall not exceed the
Band-Limited Overall Amplitude Acceptance Limit values specified
in Table 9.1A and graphed in Figure 9.1 when determined in
accordance with Sections 7.2 and 7.3 using the frequency range
defined in Section 9.1.1.2.
FREQUENCY RANGE
STANDARD
Hz (CPM)
SPECIAL
PRECISION
MM/SEC - RMS
MM/SEC RMS
MM/SEC RMS
(INCH/SEC - PEAK)
(INCH/SEC - PEAK)
(INCH/SEC - PEAK)
0.718
(0.04)
0.718
(0.04)
0.36
(0.02)
[0.81.2] x RPM
1.35
(0.075)
0.718
(0.04)
0.36
(0.02)
[1.23.5] x RPM
0.718
(0.04)
0.718
(0.04)
0.18
(0.01)
[3.58.5] x RPM
0.54
(0.03)
0.54
(0.03)
0.18
(0.01)
8.5 x RPM1,000 Hz
0.54
(0.03)
0.54
(0.03)
0.09
(0.005)
0.54
(0.03)
0.54
(0.03)
0.09
(0.005)
(60,000 CPM)
6
[1,000 2,000] Hz
(60,000 120,000) CPM)
FREQUENCY RANGE
STANDARD
SPECIAL
PRECISION
Hz (CPM)
0.3 x RPM 5K Hz
0.35
(0.5)
0.35
(0.5)
0.176
(0.25)
(300K CPM)
FOR SPECIAL
FOR PRECISION
FOR OTHER
Vibration data and signatures must be submitted with the motor to the customer's
Maintenance Department or other authorized representative before acceptance of the motor
will be authorized.
STANDARD MOTOR
LINE AMPLITUDE ACCEPTANCE LIMITS
O
C
I
V
E
L
1.35
(0.075)
0.718
(0.04)
0.718
(0.04)
T
Y
BAND BAND BAND
1
2
3
MM/SEC-RMS
(IN/SEC-Peak))
O
0.54
(0.03)
BAND 4
BAND
4
0.54
(0.03)
0.54
(0.03)
C
I
T
Y
BAND
5
BAND
6
2 3 4 5 6 7 8 9 10 11
Fmax = 2,000 Hz
(120K CPM)
RUNNING SPEED [ORDERS]
STANDARD MOTOR - - - UTILITY OPERATIONS
BAND BAND
1
2
MM/SEC-RMS
(IN/SEC-Peak)
BAND
3
2
0.54
(0.03)
BAND
4
BAND
4
0.54
(0.03)
BAND
5
4 5 6 7 8 9 10 11
0.54
(0.03)
BAND
6
Fmax = 2,000 Hz
(120K CPM)
PRECISION MOTOR
LINE AMPLITUDE ACCEPTANCE LIMITS
V
E
L
.36 .36
(.02) (.02)
O
C
I
T
Y
L
E
.18
(.01)
.18
(.01)
.09
(.005)
(IN/SEC-Peak)
A
C
C
E
.09
(.005)
BAND
6
Fmax = 2,000 Hz
(120K CPM)
R
A
T
I
O
N
g's - RMS
(g's - Peak)
BAND 1
0.35 g's - RMS (0.5 g's - Peak)
STANDARD MOTOR & SPECIAL MOTOR
FREQUENCY - CPM
Fmax = 5K Hz
(300K CPM)
V
E
L
SPECIAL MOTOR
LINE AMPLITUDE ACCEPTANCE LIMITS
Section - Spindles
YOUR COMPANY VIBRATION STANDARDS
FOR MACHINE TOOL SPINDLES AND HEADS
Measurement Locations:
Vibration measurement locations shall be;
at a point as close to the spindle bearing as possible and in line with the spindle
center line
FREQUENCY
RANGE
Hz
VELOCITY
MM/SEC RMS
(CPM)
(INCH/SEC - PEAK)
0.18
(0.01)
0.18
(0.01)
0.18
(0.01)
0.09
(0.005)
Roller Bearings
0.135
(0.0075)
FREQUENCY RANGE
ACCELERATION
gs RMS
Hz (CPM)
1
(g's PEAK)
0.3 x RPM -
0.35
(0.5)
0.71
(1.0)
1.06
(1.5)
VE
V .018
L
E .016
O
L .014
CI
.012
O TY
.010
C
.008
I
.006
T
.004
Y
.002
0.3-0.8
0.8-1.2
1.2-3.5
0.3-0.8
RPM
0.8-1.2
RPM
1.2-3.5
RPM
0.01
0.18
0.01
0.18
0.01
0.18
(0.01)
(0.01)
(0.01)
BAND 2
BAND 3
BAND 1
MM/SEC-RMS
(IN/SEC)
(IN/SEC-Peak)
3.5 - Fmax
3.5-Fmax
BAND 4
4 5 6 7 8 9 10 11
FMAX
= 2 KHz (120 KCPM)
120
KCPM
RUNNING
RUNNINGSPEED
SPEED[ORDERS]
ORDERS
1.06 g - RMS (1.5 g - Peak) for > 1000 RPM [Roller Bearings]
1.5 g(Peak) > 1000 RPM - Roller Bearings
L
L
E
R
A
T
I
O
N
E
R
A0.5
T
I
O
N
g's
BAND
0.3 x RPM
Fmax = 600K
FREQUENCY - CPM
FOR GEARLESS TYPE SPINDLES 600 to 12,000 RPM
<= 400,000 DN
Figure 0-5 Band-Limited Overall Amplitude Acceptance Limits for Gearless Type Spindles 600 to
12,000 RPM
FREQUENCY RANGE
Hz (CPM)
MICROMETER
(MILS))
2.54
(0.1)
2.54
(0.1)
VELOCITY
MM/SEC RMS
[1.2 3.5] x RPM
3
4
(INCH/SEC - PEAK)
0.18
(30,000 CPM)
(0.01)
0.09
(0.005)
Roller Bearings
0.135
(0.0075)
FREQUENCY RANGE
ACCELERATION
gs RMS
Hz (CPM)
0.3 x RPM 1,000 Hz
CPM)
DISPLACEMENT
.18
.16
.14
.12
.10
.08
.06
.04
.02
MICROMETERS
(MILS)
(MILS)
0.3-0.8
RPM
0.8-1.2
RPM
2.54
2.54
(0.1)
(0.1)
BAND 1
BAND 2
(60K
0.35
(0.5)
Roller Bearings
0.53
(0.75)
.018
.016
.014
.012
VELOCITY
(g's PEAK)
.010
.008
.006
.004
.002
0.18
(0.01)
MM/SEC
- RMS
(IN/SEC)
(IN/SEC - Peak)
Figure 0-6 Line Amplitude Acceptance Limits for Gearless Type Spindles <600 RPM
5
1.06 g - RMS (1.5 g - Peak) for > 1000 RPM [Roller Bearings]
LE
EL
RE
AR
0.5
TA
T
I
OI
NO
BAND
g's
0.3 x RPM
Fmax = 60K
FREQUENCY - CPM
FOR GEARLESS TYPE SPINDLES 600 to 12,000 RPM
<= 400,000 DN
Figure 0-7 Band-Limited Overall Amplitude Acceptance Limits for Gearless Type Spindles <60
RPM
Limits for Motorized Spindles:
Motorized Spindles shall be tested as a complete assembly (motor & spindle).
The complete assembly must meet the vibration limits specified in Section
9.2.2.1 "LIMITS FOR BOX AND CARTRIDGE-TYPE SPINDLES".
Limits for Multi-spindle (Clusters) Non-Gear Type Assemblies:
Belt driven Multi-Spindle Clusters (Reference Figure 9.2.1B) shall be tested
as a complete assembly.
The complete assembly must meet the vibration limits specified in Section
9.2.2.1 "LIMITS FOR BOX AND CARTRIDGE-TYPE SPINDLES".
Limits for Gear Driven Spindle Assemblies:
For gear driven spindle assemblies the frequency range of measurement shall
be from 0.3 x lowest shaft running speed to 3.5 x highest Gear Mesh
Frequency (GMF) unless otherwise specified. The number of lines of
resolution shall be sufficient to resolve the 1 x lowest shaft speed sidebands
at GMF.
In the velocity spectra and the acceleration spectra, the line amplitude of the
GMF sidebands must be less than (<) 0.5 times the line amplitude of the
GMF The line amplitude of sidebands of harmonics of the GMFmust also be
<.5 X the line amplitude of the GMF harmonics.
7
In the velocity spectra the line amplitude of GMF harmonics must not exceed
0.2 x GMF line amplitude.
The maximum velocity band-limited overall amplitude (Inch/sec - Peak) of
vibration at locations specified and illustrated in Figure, in any direction (as
defined in Section 4) shall not exceed the Band-Limited Overall Amplitude
Acceptance Limits specified in Table and graphed in Figure when determined
in accordance with Section.
FREQUENCY RANGE
Hz (CPM)
VELOCITY
MM/SEC RMS
1.4
(INCH/SEC - PEAK)
(0.08)
to
3.5 x Highest GMF
VELOCITY
MM/SEC - RMS
(IN/SEC - Peak)
BAND 1
Figure 0-8 Band-Limited Overall Amplitude Acceptance Limits for Gear-Driven Spindle
Assemblies
The maximum Line Amplitude of vibration in each Band at all bearing positions in any
direction (radial and axial) as required by Table shall be listed in tabular form.
The maximum Band Limited Overall Amplitude of vibration at all bearing positions in any
direction (radial and axial) as required by Table shall be listed in tabular form.
Vibration signatures of velocity and acceleration for Radial vibration measurements taken
at 0o and 90o, at each bearing Position and one (1) Axial Position shall be submitted as part
of the spindle certification. If at any bearing Position, due to machine mounting
constraints, radial vibration readings at 0o and 90o are not accessible, then two accessible
radial readings 90o apart shall be taken at said Position.
Vibration data and signatures must be submitted with the motor to the customer's
Maintenance Department or other authorized representative before acceptance of the
spindle/machine will be authorized.
BALANCE LIMITS FOR SPINDLE COMPONENTS
Any spindle component that rotates with the spindle (e.g. tooling, tool holder, sheave, chuck,
fixture, actuator, etc.) to be mounted on a spindle, shall be balanced to an ISO Balance
Quality Grade (G) that is equal to or less-than that for that spindle. [ISO Balance Quality
Grade (G) for the spindle to be obtained from the spindle manufacturer].
If the ISO Balance Quality Grade of the spindle is not known, the spindle component shall be
balanced to an ISO Grade 0.4 or less. (ISO G = 0.4 is the recommended balance quality
grade for spindles).
Any spindle component, when fastened to the spindle, and rotated at running speed, shall not
increase the vibration readings taken on the spindle above those specified in Figures and
Tables.
Variable Diameter Tooling:
A variable diameter tool holder shall always be balanced to an ISO Balance
Quality Grade (G) that is equal to or less-than that specified for the spindle
that it is used on. This balancing requirement applies at all machining
positions, as well as when the tool is rotating in any idle or retracted position.
If the spindles balance grade is not known, then the ISO Grade G 0.4 will be
used.
Any tooling/tool holder whose position and/or rotational diameter changes
during the machine cycle, when fastened to the spindle, and rotated at running
speed, shall not increase the vibration readings taken on the spindle above
those specified in Figures and Tables.
Rotating Chucks or Fixtures with Parts:
Rotating part holders (Chucks or Fixtures) shall be balanced so that the
spindles vibration readings do not increase above those shown in Figures
and Tables when turned with part at running speed.
If the vibration limits of the spindle are not known, then the chuck or fixture
shall be balanced to ISO Grade G 0.4.
SECTION - Fans
YOUR COMPANY VIBRATION STANDARDS
FOR FANS
Fans are defined as:
All non-positive displacement air handling units including Induced Draft (ID) Fans, Forced Draft
(FD) Fans, Overhung Fans, Centerhung Fans, Centrifugal, Vaneaxial, Tubeaxial, Blowers, etc.
BALANCING
Permanently attached balancing weights must be secured by welding, bolting, pop-riveting,
or of a clip-on design.
Clip-on balancing weights can only be used on centrifugal type fans and
must be located and attached on the ID pitch of the blades such that the rotational
motion of the fan creates a positive seating of the clip-on weight against the fan
blade.
NOTE: It is recommended that components (rotor, shaft, sheave) be balanced individually and then
trim balanced as a total assembly.
SHAFT TOLERANCE
Fan shaft diameter shall meet bearing manufacturer specifications for ground shaft tolerances.
RESONANCE
Natural frequencies of the completely assembled fan unit shall not be excited at the operating
speed. (Running speed should be at least 25% removed from a natural frequency of the system).
LIMITS
Fans shall be tested under installation mounting conditions. If such conditions are unknown, then
the fan shall be tested using isolation mounting per the requirements set forth in Section 9.1 on
Motors.
New and Rebuilt/Repaired Fans shall conform to the vibration limits specified in Table
when operating at specified system CFM and Fan Static Pressure.
The frequency range for fan certification shall be from Fmin = 0.3 X Running Speed of Fan
to 2,000 Hertz (120,000 CPM) for velocity and to 5,000 Hertz (300,000 CPM) for
acceleration.
Deleted: 6
Deleted: 12
For fan speeds up to 3600 RPM, the maximum velocity amplitude of vibration at all bearing
positions in any direction radial or axial shall not exceed the Line Amplitude Band Limit
values specified in Table 9.3 and graphed in Figure.
For fan speeds up to 3600 RPM, the Band-Limited Overall vibration level of acceleration at
all bearing locations in any direction radial or axial shall not exceed the Band-Limited
Overall Amplitude Acceptance Limit values specified in and graphed in Figure.
Acceptance limits for fans running over 3600 RPM shall be specified by the customer.
FREQUENCY RANGE
Hz
(CPM)
VELOCITY
MM/SEC RMS
(INCH/SEC - PEAK)
1.35
(0.075)
0.718
(0.04)
0.54
(0.03)
0.718
(0.04)
Deleted: 6
(120,000 CPM)
ACCELERATION BAND LIMITED OVERALL AMPLITUDE D LIMITS
gs RMS
1
0.35
(g's PEAK)
0.5
Deleted: 12
(300,000 CPM)
FAN
LINE AMPLITUDE ACCEPTANCE LIMITS
V
E
L
O
C
I
T
Y
1.35
(0.075)
0.718
(0.04)
0.718
(0.04)
BAND 1 BAND 2
MM/SEC-RMS
(IN/SEC-Peak)
0.54
(0.03)
BAND 3
BAND
4
BAND
Fmax = 2,000 Hz
3
4 5 6 7 8 9 10 11
(120K cpm)
RUNNING SPEED [ORDERS]
A
CA
CC
1.0
EC
E 0.9
L
L 0.8
E
E 0.7
RR
0.6
AA
0.5
TT 0.4
II
0.3
OO
0.2
NN
0.1
0.35
(0.5)
BAND 1
Fmax
Fmax
= 5,000
=120K
Hz
Fmin = .3 x RPM
FREQUENCY
- CPM
FREQUENCY
(300 K CPM)
The maximum Line Amplitude of vibration in each Band at all bearing positions in any
direction (radial and axial) as required by Table shall be listed in tabular form.
The maximum Band Limited Overall Amplitude of vibration at all bearing positions in any
direction (radial and axial) as required by Table shall be listed in tabular form.
Vibration signatures of velocity and acceleration for Radial vibration measurements taken
at 0o and 90o, at each bearing Position and one (1) Axial Position shall be submitted as part
of the fan certification. If at any bearing Position, due to machine mounting constraints,
radial vibration readings at 0o and 90o are not accessible, then two accessible radial readings
90o apart shall be taken at said Position.
Vibration data and signatures must be submitted with the fan to the customer's
Maintenance Department or other authorized representative before acceptance of the
fan/machine will be authorized.
SECTION - Pumps
YOUR COMPANY VIBRATION STANDARDS
FOR PUMPS
Pumps shall be defined in two (2) categories:
Positive Displacement --including, but not limited to Piston, Gear, and Vane.
Centrifugal
OPERATING CONDITIONS
FREQUENCY RANGE
VELOCITY
Hz (CPM)
MM/SEC RMS
0.718
(0.04)
1.35
(0.075)
0.718
(0.04)
0.54
(0.03)
PUMPING FREQ.
FREQUENCY RANGE
BAND (PF)
Hz (CPM)
BAND 5
5 Lines of resolution
centered on PF.
(INCH/SEC - PEAK)
VELOCITY
MM/SEC RMS
(INCH/SEC - PEAK)
PISTON
1.35
(0.075)
VANE
0.89
(0.05)
FREQUENCY RANGE
ACCELERATION
gs RMS
Hz (CPM)
1
0.3 x RPM 5K Hz
(300K CPM)
(g's PEAK)
POSITIVE DISPLACEMENT
1.06
(1.5)
NON-POSITIVE DISPLACEMENT
0.707
(1.0)
V
E
BAND
5
Line of Resolution
containing Pumping
Frequency
1.35
(0.075) PISTON
-2 Lines
C
I
0.89
(0.05)
0.718
(0.04)
0.718
(0.04)
0.54
.03
(0.03)
T
Y
BAND 1
MM/SEC - RMS
(IN/SEC - Peak)
BAND 2
BAND 3
VANE
BAND 5
4 5 6 7
+2 Lines
PF
PF BAND
BAND 4
10
11
Fmax = 2,000 Hz
(120K CPM)
NOTE: BAND 5 IS A FLOATING BAND WITH BANDWIDTH OF THE PUMPING FREQUENCY +- 2 LINES OF RESOLUTION
ACCEPTANCE LIMITS FOR BAND 5 ARE BAND LIMITED OVERALL AMPLITUDE VIBRATION LEVELS
Figure 0-1 Line Amplitude Acceptance Limits for Positive Displacement & Centrifugal Pumps
ACCELERATION
g's - RMS
(g's - Peak)
BAND 1
1.06g-RMS (1.5g-Peak) POSITIVE DISPLACEMENT
FREQUENCY - CPM
Fmax = 5K Hz
(300K CPM)
Figure 0-2 Band-Limited Overall Amplitude Acceptance Limits for Positive Displacement &
Centrifugal Pumps
VERTICAL MOUNTED PUMPS
Vertically mounted pump systems with a Vertical Mount Height greater than 1.5 meters
will have an allowable increase in Velocity Amplitude Acceptance Limits in Bands 1, 2, and
3 of 16 per meter of Vertical Mount Height greater than 1.5 meters (5 feet). [e.g. A 2
3
meter Vertical Mount Height would yield a 7.5% increase [(2 meter - 1.5 meter) x
15%/meter]) in the Table 9.4 Velocity Amplitude Acceptance Limits specified for Bands 1,
2, and 3). Therefore the limit for Band 1 would be 0.718 MM/SEC + [(0.718 MM/SEC) x
(0.075)] = 0.77185 MM/SEC - RMS,
(0.04 Inch/sec + [(0.04 Inch/sec) x ( 0.1)] = 0.044 Inch/sec-Peak).
Vertical Mount Height is defined as the furthest measurable distance from the machine
mounting to the end of the driver or the end of the pump, which ever is greater.
PUMP CERTIFICATION
The maximum Line Amplitude of vibration in each Band at all bearing positions in any
direction (radial and axial) as required by Table 9.4 shall be listed in tabular form.
The maximum Band Limited Overall Amplitude of vibration at all bearing positions in any
direction (radial and axial) as required by Table 9.4 shall be listed in tabular form.
Vibration signatures of velocity and acceleration for Radial vibration measurements taken
at 0o and 90o, at each bearing Position and one (1) Axial Position shall be submitted as part
of the pump certification. If at any bearing Position, due to machine mounting constraints,
radial vibration readings at 0o and 90o are not accessible, then two accessible radial readings
90o apart shall be taken at said bearing Position.
Vibration data and signatures must be submitted with the pump to the customer's Maintenance
Department or other authorized representative before acceptance of the pump/machine will be
authorized.
SECTION - Gearboxes
YOUR COMPANY VIBRATION STANDARDS
FOR GEARBOXES
VIBRATION LIMITS FOR GEARBOXES
Gearboxes up to a maximum of two (2) gear sets, shall not exceed the vibration limits specified in
Table 9.5.1 and graphically illustrated in Figures 9.5.1 and 9.5.2. For gear boxes with more than
two (2) gear sets, acceptance limits will be established between customer and supplier.
Table 0-1 MAXIMUM ALLOWABLE VIBRATION LEVELS FOR GEARBOXES WITH TWO
(2) GEAR SETS
FREQUENCY RANGE
Hz (CPM)
VELOCITY
MM/SEC RMS
(INCH/SEC - PEAK)
0.718
(0.04)
1.35
(0.075)
0.718
(0.04)
0.54
(0.03)
0.54
(0.03)
0.54
(0.03)
FREQUENCY RANGE
Hz (CPM)
gs RMS
(g's PEAK)
0.35
(0.5)
GEAR BOX
LINE AMPLITUDE ACCEPTANCE LIMITS
1.35
(.075)
0.718
(.04)
BAND 1
MM/SEC - RMS
(IN/SEC - Peak)
0.718
(.04)
BAND 2
BAND 3
0.54
(.03)
0.54
(.03)
BAND
BAND 44
4 5 6 7
0.54
(.03)
BAND 5
10
BAND 6
11
GEAR BOX
BAND-LIMITED OVERALL AMPLITUDE ACCEPTANCE LIMITS
BAND 1
ACCELERATION
g's - RMS
(g's - Peak)
FREQUENCY
Vibration signatures of velocity and acceleration for Radial vibration measurements taken
at 0o and 90o, at each bearing Position and one (1) Axial Position shall be submitted as part
of the gearbox certification. If at any bearing Position, due to machine mounting
constraints, radial vibration readings at 0o and 90o are not accessible, then two accessible
radial readings 90o apart shall be taken at said Position.
Vibration data and signatures must be submitted with the gearbox to the customer's
Maintenance Department or other authorized representative before acceptance of the
gearbox/machine will be authorized.
FREQUENCY RANGE
Hz (CPM)
VELOCITY
MM/SEC RMS
(INCH/SEC - PEAK)
0.718
(0.04)
1.35
(0.075)
0.718
(0.04)
0.54
(0.03)
0.54
(0.03)
0.54
(0.03)
FREQUENCY RANGE
0.3 x RPM 5K Hz
Hz (CPM)
gs RMS
(g's PEAK)
0.35
(0.5)
Deleted: 12
(300K CPM)
VELOCITY
MM/SEC - RMS
(IN/SEC - Peak)
0.718
(0.04)
BAND 1
0.718
(0.04)
BAND 2
BAND 3
0.54
(0.03)
0.54
(0.03)
BAND 44
BAND
4 5 6 7
BAND 5
10
0.54
(0.03)
BAND 6
11
Fmax = 2,000 Hz
(120K CPM)
ACCELERATION
g's - RMS
(g's - Peak)
Figure 0-1 Line Amplitude Acceptance Limits for Non-Machine Tools and Non-Precision Machine
Tools
FREQUENCY
Fmax = 5K Hz
(300K CPM)
Figure 0-2 Band-Limited Overall Amplitude Acceptance Limits for Non-Machine Tools & NonPrecision Machine Tools
PRECISION MACHINE TOOLS
Precision Machine Tools shall not exceed the Vibration Limits specified in Table and graphically
illustrated in Figures.
FREQUENCY RANGE
VELOCITY
Hz (CPM)
MM/SEC RMS
0.36
(0.02)
0.36
(0.02)
0.18
(0.01)
(INCH/SEC - PEAK)
0.09
(0.005)
Roller Bearings
0.135
(0.0075)
FREQUENCY RANGE
ACCELERATION
gs RMS
Hz (CPM)
0.3 x RPM 10K Hz
(600K CPM)
(g's PEAK)
0.35
(0.5)
0.707
(1.0)
1.06
(1.5)
VELOCITY
MM/SEC - RMS
(IN/SEC - Peak)
0.36
(0.02)
0.18
(0.01)
0.135 (0.0075) - Roller Bearings
0.09 (0.005) - Angular Contact Bearings
BAND 1 BAND 2
1
BAND 3
2
BAND 4
3
10
Fmax = 2,000 Hz
(120K CPM)
Figure 0-3 Line Amplitude Acceptance Limits for Precision Machine Tools
10
R
A
T
I
O
N
1.0(1.0g
g(Peak)
<= 1000
- Roller
0.707g - RMS
- Peak)
RollerRPM
Bearings
<=Bearings
1,000 RPM
ACCELERATION
L
E
g(Peak)
> 1000
- Roller
Bearings
1.06g - RMS1.5
(1.5g
- Peak)
RollerRPM
Bearings
> 1,000
RPM
(g's - Peak)
g's - RMS
A
C
C
E
0.5
g's
BAND
0.3 x RPM
FREQUENCY
FREQUENCY
- CPM
Fmax
= 10K=Hz600K
Fmax
(600K CPM)
Figure 0-4 Band-Limited Overall Amplitude Acceptance Limits for Precision Machine Tools
11
DEFAULT CERTIFICATION
The maximum Line Amplitude of vibration in each Band at all bearing positions in any
direction (radial and axial) as required by Table 9.6.1 or 9.6.2 shall be listed in tabular form.
The maximum Band Limited Overall Amplitude of vibration at all bearing positions in any
direction (radial and axial) as required by Table 9.6.1 or 9.6.2 shall be listed in tabular form.
Vibration signatures of velocity and acceleration for Radial vibration measurements taken
at 0o and 90o, at each bearing Position and one (1) Axial Position shall be submitted as part
of the machine certification. If at any bearing Position, due to machine mounting
constraints, radial vibration readings at 0o and 90o are not accessible, then two accessible
radial readings 90o apart shall be taken at said Position.
Vibration data and signatures must be submitted with the machine to the customer's
Maintenance Department or other authorized representative before acceptance of the
machine will be authorized.
12
AUXILIARY GEARBOX
ANG
ANGLE
ARS
ARBOR SUPPORT
ASY
ASSEMBLY
BLR
BLOWER
BLT
BELT
BRG
BEARING
BRK
BRAKE
BSE
BASE
BSH
BUSHING
BTM
BOTTOM
CHN
CHAIN
CLP
CLAMP
CLS
CLUSTER
CLH
CLUTCH
CMP
COMPENSATOR
CMS
CAMSHAFT
CLT
COOLANT
CPG
COUPLING
CPR
COMPRESSOR
CRK
CRANKSHAFT
CTF
CENTRIFUGAL
CTR
CENTER
CUT
CUTTER
DBL
DOUBLE
DIE
DIE
DIS
DISTRIBUTOR
DPT
DEPARTMENT
DRV
DRIVE
DRB
DRAW BAR
DRL
DRILL
DRV
DRIVE
ENC
ENCODER
EXH
EXHAUST
FAN
FAN
FDD
FEED DRIVE
FRM
FRAME
FRT
FRONT
FWL
FLYWHEEL
FXT
FIXTURE
GBX
GEAR BOX
GEN
GENERATOR
GER
GEAR
GHD
GEARED HEAD
GIB
GIB
GRD
GUARD
GRW
GRIND WHEEL
HDS
HEADSTOCK
HED
HEAD
HSG
HOUSING
HYD
HYDRAULIC
IDL
IDLER
IDP
IDLER PULLEY
INB
IN BOARD
ITK
INTAKE
JKS
JACKSHAFT
KWY
KEYWAY
LTH
LATHE
MAG
MAGNETIC
MIL
MILLING MACHINE
MTR
MOTOR
MUL
MULTIPLE
OTB
OUTBOARD
PIN
PINION
PLB
PILLOW BLOCK
PLT
PLANT
PLY
PULLEY
PMP
PUMP
PRC
PRECISION
PSN
PISTON
QUL
QUILL
RER
REAR
RTR
ROTOR
RNR
RUNNER
SFT
SHAFT
SGL
SINGLE
SHV
SHEAVE
SLV
SLEEVE
SPK
SPROCKET
SPL
SPINDLE
SPN
SPLINE
STA
STATION
STD
STANDARD
STG
STAGE
SYS
SYSTEM
TBL
TABLE
TBO
TURBO
TDM
TANDEM
TLS
TAILSTOCK
TOL
TOOL
TOP
TOP
TRB
TURBINE
UNT
UNIT
VAC
VACUUM PUMP
VNE
VANE
WAY
WAY
WHL
WHEEL
WJK
WATER JACKET
WKH
WORK HEAD
WLH
WHEEL HEAD
WRC
WRENCH
WSR
WASHER
Other Component Symbols not listed above should be agreed upon by the machine tool builder and the
customer on an as-needed basis.
APPENDIX B - GLOSSARY
ACCELERATION: The time rate of change of velocity. Typical units are ft/sec2 and g's (1 g = 32.17
ft/sec2 = 386 in/sec2 = 9.81 meter/sec2). Acceleration measurements are made with accelerometers.
Note: By international agreement, the value 9.80665 m/s2 = 980,665 cm/s2 = 386.089 in/s2 =
32.174 ft/s2 has been chosen as the standard acceleration due to gravity (g). ISO 2041 (1990)
ACCELEROMETER:
Transducer whose output is directly proportional to acceleration. Most
commonly used are mass loaded piezoelectric crystals to produce an output proportional to acceleration.
AMPLITUDE:
A measure of the severity of vibration. Amplitude is expressed in terms of peak-topeak, zero-to-peak (peak), or rms. For pure sine waves only:
ANTI-ALIASING FILTER:
A low-pass filter designed to filter out frequencies higher than 1/2 the
sample rate in order to prevent aliasing.
ANTI-FRICTION BEARING:
AVERAGE: The sum of the values of the measurements taken divided by the number of measurements
taken.
BALANCE: When the mass center line and rotational center line of a rotor are coincident.
BALANCE QUALITY GRADE - GXXX: For rigid rotors, G, is the product of specific unbalance, e, and
rotor maximum service angular velocity. Service angular velocity is service RPM expressed in radians per
second.
G = e x = constant
BALANCING:
A procedure for adjusting the radial mass distribution of a rotor by adding or
removing weight, so that the mass centerline approaches the rotor geometric centerline achieving less
vibration amplitude at rotational speed.
BAND-LIMITED OVERALL AMPLITUDE:
For vibration level limits specified in terms of
"BAND-LIMITED OVERALL AMPLITUDE LIMITS" the Total vibration level "A" in a band, as defined
by the following equation, shall not exceed the Overall Amplitude Acceptance Limit specified for the
Band.
N
Ai2
=
i =1
Ai
=
Band
(i = 1) =
(i = N) =
W
=
Window)
BEATS:
Periodic variations in the amplitude of an oscillation resulting from the combination of two
oscillations of slightly different frequencies. The beats occur at the difference frequency. ISO 2041 (1990).
BEAT FREQUENCY:
The absolute value of the difference in frequency of two oscillations of
slightly different frequencies ISO 2041 (1990).
BIN: A frequency bandwidth (f) determined by Fmax divided by the number of lines of resolution.
While commonly referred to and represented by a line of resolution, a Bin contains a bandwidth of
frequencies. (Refer to LINE OF RESOLUTION)
BLADE PASS FREQUENCY (PUMPING FREQUENCY):
A potential vibration frequency on any
bladed machine (turbine, axial compressor, fan, pump, etc.). It is represented by the number of fan blades or
pump vanes times shaft rotating frequency.
CALIBRATION:
A test to verify the accuracy of measurement instruments. For vibration, a
transducer is subjected to a known motion, usually on a shaker table, and the output readings are verified or
adjusted.
COMPLETE MACHINE: A complete machine is defined as the entire assembly of components, subcomponents, and structure, which is monitored to perform a specific task(s). On a Complete Machine
Assembly with all individual components operating in their normal operating condition, mode, and
sequence, the Component Vibration Level Limits for the complete machine acceptance are the same as
when the component is tested individually.
CRITICAL SPEED: The speed of a rotating system corresponding to a system resonance frequency.
DECIBEL (dB):
A logarithmic representation of amplitude ratio, defined as 20 times the base ten
logarithm of the ratio of the measured amplitude to a reference. dBV readings, for example, are referenced
to 1 volt rms. dB amplitude scales are required to display the full dynamic range of an FFT Analyzer.
DISPLACEMENT: The distance traveled by a vibrating object. For purposes of this document,
displacement represents the total distance traveled by a vibrating part or surface from the maximum position
of travel in one direction to the maximum position of travel in the opposite direction (Peak-to-Peak) and is
measured in the unit mil (1 mil = 0.001 inch).
DYNAMIC RANGE:
The difference between the highest measurable signal level and the lowest
measurable signal level that is detectable for a given Amplitude Range setting. Dynamic Range is usually
expressed in decibels, typically 60 to 90 dB for modern instruments.
DYNAMIC MASS: To determine if the mass of the transducer is effecting the measurement, perform the
following steps:
a.
b.
Place a mass equivalent to the mass of the accelerometer adjacent to the measuring
accelerometer.
c.
d.
FFT ANALYZER: Vibration analyzer that uses the Fast Fourier Transform to display vibration
frequency components.
FFT (FAST FOURIER TRANSFORM): A calculation procedure which converts a time domain signal
into a frequency domain display.
FIELD BALANCING:
The process of balancing a rotor in its own bearings and supporting structure
rather than in a balancing machine.
FFT (FAST FOURIER TRANSFORM): A calculation procedure which produces a mathematical
relationship between the time domain and the frequency domain resulting in discrete frequency components
from the sampled time data.
FLEXIBLE ROTOR:
A rotor that deforms significantly at running speed. This term is used for
rotors that operate close to or above their first critical speed. A rotor is considered flexible when its speed is
more than 75% of its lowest natural frequency in bending.
FORCED VIBRATION: The oscillation of a system under the action of a forcing function. Typically
forced vibration occurs at the frequency of the exciting force.
FREE VIBRATION: Vibration of a mechanical system following an initial force -- typically at one or
more natural frequencies.
FREQUENCY:
The repetition rate of a periodic event, usually expressed in cycles per second (Hertz
-abr. HZ), cycles per minute (CPM), or multiples of rotational speed (Orders). Orders are commonly
referred to as 1X for rotational speed, 2X for twice rotational speed, etc. Frequency is the reciprocal of the
Period.
NOTE: Vibration frequencies are expressed in Hertz (cycle per sec) or CPM (cycle per minute).
Rotational speed (Running Speed) is expressed in RPM (Revolutions per minute).
FREQUENCY DOMAIN: Presentation of a signal whose amplitude is measured on the Y axis, and the
frequency is measured on the X-axis.
FREQUENCY RESOLUTION (
f)
f = (FMAX - FMIN)/# Lines of resolution. f represents
the minimum spacing between data points in the spectrum.
FMAX:
FMIN:
FREQUENCY RESPONSE:
specified frequency limits.
g: The value of acceleration produced by the force of gravity. (32.17 ft/sec2, 386 in/sec2, 9.81 m/sec2).
GEAR MESH FREQUENCY (YOUR COMPANYF):
A potential vibration frequency on any
machine that contains gears: equal to the number of teeth multiplied by the rotational frequency of the gear.
HANNING WINDOW:
An FFT window function that provides better frequency resolution than the
flat top window, but with reduced amplitude accuracy.
HARMONIC:
Frequency component at a frequency that is an integer (whole number e.g. 2X, 3X,
4X, etc.) multiple of the fundamental (reference) frequency.
HI BANDPASS FILTER: A device that separates the components of a signal and allows only those
components above a selected frequency to be amplified.
HERTZ (Hz):
INTEGRATION:
A process producing a result that when differentiated, yields the original quantity.
Integration of acceleration, for example, yields velocity. Integration is performed in an FFT Analyzer by
3
dividing by 2f where f is the frequency of vibration. Integration is also used to convert velocity to
displacement.)
LARGE APPARATUS AC/DC MOTORS:
Reference NEMA Publication No. MG 1, Motors and
Generators, Section III LARGE MACHINES, Part 20. Induction Machines, Part 21. Synchronous Motors,
and Part 23. DC Motors.
LINEAR NON-OVERLAPPING AVERAGE: An averaging process where each Time block sample
used in the averaging process contains data not contained in other Time blocks (i.e. Non-overlapping) used
in the averaging. Linear averaging is performed in the Frequency Domain, and each sample is weighted
equally.
LINES:
BIN
The total number of data points in a spectrum (e.g. 400, 800, 1600, etc.). See also
PEAK:
Refers to the maximum of the units being measured, i.e., peak velocity, peak acceleration,
peak displacement.
PEAK-TO-PEAK: Refers to the displacement from one travel extreme to the other travel extreme. In
English units, this is measured in mils (.001 inch) and in metric units it is expressed in micro-meter M
(.000001 meters).
PERIOD:
The amount of time, usually expressed in seconds or minutes, required to complete one cycle
of motion of a vibrating machine or machine part. The reciprocal of the period is the frequency of vibration.
PHASE (PHASE ANGLE): The relative position, measured in degrees, of a vibrating part at any instant
in time to a fixed point or another vibrating part. The Phase Angle (usually in degrees) is the angle between
the instantaneous position of a vibrating part and the reference position. It represents the portion of the
vibration cycle through which the part has moved relative to the reference position .
PRECISION SPINDLE:
speed, or both.
RADIAL MEASUREMENT:
RADIAL VIBRATION:
Shaft dynamic motion or casing vibration which is in a direction
perpendicular to the shaft centerline.
RESONANCE:
The condition of vibration amplitude and phase change response caused by a
corresponding system sensitivity to a particular forcing frequency. A resonance is typically identified by a
substantial amplitude increase and related phase shift.
RIGID ROTOR:
A rotor that does not deform significantly at running speed. A rotor whose parts do
not take up motion relative to each other, i.e., all points move in the same direction at the same instant of
time. A rotor is considered rigid when its speed is less than 75% of its lowest natural frequency in bending.
RMS: (Root mean square) Equal to 0.707 times the peak of a sinusoidal signal.
ROLLING ELEMENT BEARING:
Bearing whose low friction qualities derive from rolling
elements (balls or rollers), with little lubrication.
ROTATIONAL SPEED:
time, e.g., 1800 RPM.
The number of times an object completes one complete revolution per unit of
SIDE BAND: Equals the frequency of interest plus or minus one times the frequency of the exciting force.
SIGNATURE (SPECTRUM):
Term usually applied to the vibration frequency spectrum which is
distinctive and special to a machine or component, system or subsystem at a specific point in time, under
specific machine operating conditions, etc. Usually presented as a plot of vibration amplitude
(displacement, velocity or acceleration) versus time or versus frequency. When the amplitude is plotted
against time it is usually referred to as the TIME WAVE FORM.
SMALL (FRACTIONAL) AND MEDIUM (INTEGRAL) HORSEPOWER AC/DC MOTORS:
Reference NEMA Publication No. MG 1, Section II SMALL (FRACTIONAL) AND MEDIUM
(INTEGRAL) MACHINES, Part 12. Tests and Performance - AC and DC Motors.
SOFTFOOT: A condition that exists when the bottom of all of the feet of a machine are not in the same
plane (can be compared to a chair with one short leg). Softfoot is present if the machine frame distorts when
a foot bolt is loosened or tightened. It must be corrected before the machine is actually aligned.
TIME DOMAIN:
Presentation of a signal whose amplitude is measured on the Y axis and the time
period is measured on the X axis.
TRANSDUCER (PICKUP) - VIBRATION:
A device that converts shock or vibratory motion into
an electrical signal that is proportional to a parameter of the vibration measured. Transducer selection is
related to the frequencies of vibration which are important to the analysis of the specific machine(s) being
evaluated/analyzed.
TRUE PEAK:
The actual maximum amplitude of a complex waveform. Must be measured in the
Time Domain. Peaks measured in the Frequency Domain represent the amplitudes of the Fourier Series
sinewave components that have resulted from the Fourier Transform of the Time Waveform. These
sinewave components when added together, by both amplitude and phase, will result in the true Time
Waveform
UNBALANCE: Unequal radial weight distribution of a rotor system; a shaft condition such that the mass
and shaft geometric centerlines do not coincide. There are three principle types of unbalance:
1. Static Unbalance - that condition of unbalance for which the central principle axis is
displaced only parallel to the shaft axis.
2. Couple Unbalance - that condition of unbalance for which the central principle axis
intersects the shaft axis at the center of gravity.
3. Dynamic Unbalance - that condition of unbalance for which the central principle axis
is not parallel to and does not intersect the shaft axis. (Dynamic Unbalance is a
5
combination of static and couple unbalance. This is the type of unbalance usually
found.)
VELOCITY: The time rate of change of displacement with respect to some reference position. For
purposes of this document, velocity is measured in the units Inch per second-Peak.
NOTE: THE REFERENCE FOR MANY OF THE DEFINITIONS IN THIS GLOSSARY IS THE
GLOSSARY FROM THE HEWLETT PACKARD PUBLICATION "EFFECTIVE MACHINERY
MEASUREMENTS USING DYNAMIC SIGNAL ANALYZERS," APPLICATION NOTE 243-1
YOUR COMPANY
VENDORS - VIBRATION DATA FORM AND CERTIFICATION
SHEET
This form must accompany the machine certification vibration data . Vibration data
must be presented in the YOUR COMPANY Standard Data Base structure. (Reference
Sections 4.0 and 5.0 of YOUR COMPANY Specification V1.0-1997)
_____________________________________________________________________
___________________________________
Issued
By:
Division:________________________________Plant:_______________________
______________________
Address:___________________________________________________________
_______________________
__________________________________________________________________
________________
A. MACHINE SPECIFICATIONS
Builder:______________________________________________________________
___________________________________
Machine/Equipment
Identification
Name:________________________________________________________________
_______________________
Purchase Order No._________________________________________ Capital Tag
No.__________________________
TYPE:_______________________________________________________MODEL:_
__________________________________
SERIAL
NO.__________________________________________________CAPACITY:_____
___________________________
SPEED:____________________________HORSEPOWER:_________________AU
XILIARIES:_________________________
B. INSTRUMENTATION USED FOR CERTIFICATION
Instrument
Model
Serial No.
Certified
Calibration Date
Vibration Meter
Vibration Transducer
Vibration Analyzer
Vibration Software
Other:
C. CERTIFICATION
Date:___________________________
Signed:_______________________________________________________________
___
Title:__________________________________
Company:_________________________________________________________
D. ACCEPTANCE
_____________________________________________________________________
_
_________________________
Customer Authorized Representative
Date
Page
____________ of___________
YOUR COMPANY
VENDORS - VIBRATION DATA FORM AND CERTIFICATION
SHEET
MACHINE INFORMATION DATA SHEET
MACHINE NAME__________________________________
CODE:_________________________________
MACHINE
ID
DRIVER INFORMATION
DRIVER TYPE:___________________
HP:________
BRAND:________________ RPM:_________________
MANUFACTURER ID#:____________________________
FRAME #:__________________
BEARINGS:
OUTBOARD:
ID#____________________________________
INBOARD:
ID#___________________________________
CONSTANT
SPEED?______
Manufacturer______________________________Bearing
Manufacturer________________________________Bearing
SLEEVE
ROLLING ELEMENT
IF
DIRECT
COUPLED,
TYPE
COUPLING:____________________________________________________________________________
OF
OF
LIST
ALL
SHEAVES
WITH
CORRESPONDING
DIAMETER:________________________________________________________
PITCH
___________________________________________________________________________________________
________________________
BELT LENGTH:_________________________
SHEAVES:_____________________
GEARBOX?____________ IF
I/O RATIO:__________
YES,
OR
CENTER-TO-CENTER
DISTANCE
OF
MANUFACTURER:________________________________________
SHAFT
# OF TEETH
BEARING ID#
1ST INTERMEDIATE
2ND INTERMEDIATE
3RD INTERMEDIATE
OUTPUT
DRIVEN INFORMATION
DRIVEN
TYPE
(FAN,
PUMP,
GENERATOR,
ETC.)____________________________________________________________
MANUFACTURER:_______________________________
RPM:_____________
PISTONS
BEARINGS:
OUTBOARD:
ID#____________________________________
INBOARD:
ID#___________________________________
SPINDLE,
MANUF.ID#:________________________
BLADES
OTHER
(CIRCLE
Manufacturer______________________________Bearing
Manufacturer________________________________Bearing
SLEEVE
ROLLING ELEMENT
COMMENTS:
10
Page
____________ of___________
YOUR COMPANY
VENDORS - VIBRATION DATA FORM AND CERTIFICATION
SHEET
Machine Layout Drawing Indicating Vibration Measurement Locations per
Section 5.7
EXAMPLE
003
004
002
005
006
: 31,920
Gear Box
Gear Mesh Freq.: 45,600 CPM
Driven Shaft: 912 RPM
Gear Mesh Freq.
1200 RPM
Motor
38T
35T
912 RPM
31,920 CPM
GMF
47T
679 RPM
Gear Reducer
Provide Gear Mesh Frequencies in CPM
Provice Shaft Speed in RPM
11
12
Page
____________ of___________
YOUR COMPANY
VENDORS - VIBRATION DATA FORM AND CERTIFICATION
SHEET
Machine Layout Drawing Indicating Vibration Measurement Locations per
Section 5.7
Contd.
13