Vibration Analysis

Basic Concepts

What is Vibration ?
Vibration is a pulsating motion of a machine or a machine part from its original position of rest and
can be represented by the formula :

Vibration Amplitude Response =

Dynamic Force Dynamic Resistance

Force Balance
K
M C

1. The Exciting Force F such as Unbalance

2. The mass of vibrating system M 3. The stiffness of vibrating system K 4. The damping characteristics C

Vibration Characteristics

Amplitude Frequency
Phase Direction

Vibration Characteristics

Amplitude Frequency
Phase Direction

Vibration Displacement
Max Displacement

DISPLACEMENT

Minimum Displacement

Pk-Pk

Time

Amplitude Units

Displacement

Pk-Pk

mils or microns

Vibration Velocity
Max Velocity

RMS

Velocity

Minimum Velocity

RMS of a Sinusoidal Wave

1 T = __ f

Where T = period of one cycle of the vibration vi = instantaneous velocity t = the variable time

Amplitude Units

Displacement

Pk-Pk

mils or microns

Velocity

RMS

in/sec or mm/sec

Vibration Acceleration
Max Acceleration

Acceleration

Pk

Minimum Acceleration

Amplitude Units (Metric)

Displacement

Pk-Pk

microns

Velocity

RMS

mm/sec
gs

Acceleration

Pk

Amplitude Units (Imperial)

Displacement

Pk-Pk

mils

Velocity

Pk

in/sec
gs

Acceleration

RMS

Comparison of Amplitude Units

Displacement

Velocity

Acceleration

What do they measure?

Displacement

How far it moves Mils or Microns How fast it moves in/sec or mm/sec How quickly velocity changes g or in/sec2 or mm/sec2

Velocity

Acceleration

How Much is too Much ?

Manufacturers specified limits End User limits Comparison with identical machines Same Load, Mounting, Temp, Pressure Standards specific to type BS 4999 part 142 Electric Motors General Standards BS-4675 (ISO-2372), VDI - 2056 Historical Data

Conversion of Parameters
METRIC UNITS
Where: D=Peak-To-Peak Displacement (m Pk-Pk) V=Peak Velocity (mm/sec Pk) A=Peak Acceleration (gs-Pk) F=Frequency (CPM)

V = DF 19,100 D = 9,100V F

V = 3690 A F A= VF 3690

A=

DF2 70,470,910

D = 70,470,910 F2

Conversion of Parameters
ENGLISH UNITS
Where: D=Peak-To-Peak Displacement (Mils Pk-Pk) V=Peak Velocity (in/sec Pk) A=Peak Acceleration (gs-Pk) F=Frequency (CPM)

V = DF 19,100 D = 19,100V F

V = 93640 A F A= VF 93,640

A=

DF2 1,790,000,000

D = 1,790,000,000 F2

Amplitude Units

Acceleration - G-s Value from the base line to the peak amplitude Looks a force generated in our machine (High frequency domain)

Velocity RMS - MM/Sec

RMS - root mean square, appears at 0.707 the value of the amplitude

Displacement - microns
Total movement, value is from Peak to Peak Ignores all high frequencies and looks at the low frequency

Gives a good overall picture, of the vibration in our machine

Vibration Characteristics

Amplitude Frequency
Phase Direction

Vibration Frequency
Vibration Frequency is simply a measure of the numbers of complete cycles that occur in a specified period of time such as Cycles per
Second or Cycles per Minute. Frequency is related to the period of vibration by this simple formula : Frequency = 1 / Period

Vibration Frequency

DISPLACEMENT

0.5

1.0

Time, mili sec

Time Period = 1.0 mili sec Frequency = 1 / Time Period Frequency = 1 / 10-3 CPS Frequency = 1000 CPS or Hz Frequency = 1000*60 CPM Frequency = 60 kCPM

Significance of Frequency
The forces that cause vibration are usually generated through the rotating motion of the machine parts. These forces change in direction or amplitude according to rotational speed of the machine components, most vibration problems will have frequencies that are directly related to the rotational speeds. Vibration Frequency is an Analysis or Diagnostic Tool

Vibration Frequency & Likely Causes

Frequency In Terms of RPM 1 X RPM Most Likely Cause Unbalance Other Possible Causes and Remarks 1. Eccentric Journals 2. Misalignment or bent shaft if High Axial Vibration 3. Bad belts if RPM of belt 4. Resonance 5. Reciprocating Forces 6. Electric Problems 1. Misalignment if high axial vibration 2. Reciprocating Forces 3. Resonance 4. Bad belts if 2 X RPM of belt Usually a combination of misalignment and excessive axial clearances (looseness) 1. Bad Belt Drives 2. Background Vibration 3. Sub-Harmonic Resonance 4. Beat Vibrations Common Electrical Problems include broken rotor bars, unbalanced phases in poly-phase system, unequal airgap Rare as a possible unless resonance is exited 1. 2. 3. 4. 1. 2. 3. 4. Gear Teeth times RPM if bad gear Number of fan blades times RPM Number of impeller vanes times RPM May occur 2,3,4 and sometimes higher harmonics if severe looseness Bearing Vibration Cavitation, recirculation and flow turbulance cause random, high frequency vibration Improper lubricationof journal bearing (friction exciting vibration Rubbing

2 X RPM

Mechanical Looseness

3 X RPM Less than 1 X RPM

Misalignment Oil Whirl (Less than RPM)

Synchronous AC Line Frequency 2 X Synchronous Line Frequency Many Times RPM Harmonically Related

Electrical Problems Torque Pulses Bad Gears Aerodynamic Forces Hydraulic Forces Mechanical Looseness Reciprocating Forces Bad Anti Friction Bearings

High Frequency Not Harmonically Related

Comparison of Parameters
F (CPM) 60 600 6,000 60,000 600,000
Displacement

D (um) 100.00 10.00 1.00 0.10 0.01

V (mm/s) 0.314 0.314 0.314 0.314 0.314

A (g) 0.0002 0.002 0.020 0.201 2.012

Force Indicator

10 um

.20 g
Fatigue Indicator .314 mm/s Acceleration .1 um Stress Indicator

LOG AMPLITUDE (um, mm/s, g)

Velocity .314 mm/s .002 g

60

600

6K

120K

600K

LOG FREQUENCY (CPM)

Vibration Characteristics

Amplitude Frequency
Phase Direction

What is Phase ?

The angular reference at a given frequency at one instance in time of a moving part to a fixed point
The angular reference at a given frequency at one instance in time of two moving parts to a fixed point

Vibration Phase
Phase is simply a convenient means of determining the relative motion of two vibrating
parts of machines. It is measured in degrees or clocks.

Vibration Phase

Phase Relationship as Used With Machinery Vibration

Phase - Phase Vs Amplitude Units

What we are going to see now is the significant difference between the phase relationships of the three different amplitude units. This is governed by the laws of physics
Using Displacement as the base unit, then readings taken in Velocity will lead Displacement by 90. Acceleration will lead Velocity by 90, therefor leading Displacement by 180.
Displacement Waveform Velocity Waveform Acceleration Waveform +90

+90

It is important to understand the phase shifts with different amplitude units, especially when comparing new data to previous data if the units are different.

Phase - Acquiring Phase Data

How does the cross channel collect phase data, if phase is the relationship between the peak value and the 1x Ts Pulse?

Cross channel uses the first transducer as a reference point, and the second transducer as the comparison.
Taking the peak value from both waveforms over the same period of time and calculating the difference in the same way as before

Cross Channel Phase

Phase - Acquiring Phase Data

As stated earlier phase data can be acquired by two means:

Single Channel
Dual Channel

Single Channel Phase Acquisition - How it Works!

Single Channel Phase

The Phase Angle is calculated using the formula:

Phase Angle =
(Difference in Time) X 360 (Time of 1 Revolution)

Phase - Amplitude Characteristics

In basic vibration training you were introduced to the three units to measure amplitude:
Velocity
The most common unit used for trending data

Defined as the Rate of Movement

Acceleration
Used for high speed machinery were impacting is common - Gears, Trouble Shooting Bearings, Peakvue Defined as Change in Velocity over a period of time

Displacement
Mainly used when looking at relative motion or slow speed machines

Defined as Total movement from a reference point

Phase - Amplitude Characteristics

Basic vibration also introduced to the effects each unit has on the spectral data
Velocity
Gives you a good overall level of vibration of both high frequency and low frequency data

Acceleration
Accentuates the high frequencies and ignores the low frequencies. Good for looking at impacts.

Displacement
Looks at the low frequency data (relative motion) and ignores the high frequency impacting

As expected, the amplitude units effect the time domain much in the same way they do the frequency domain

Phase - Amplitude Characteristics

Displacement
The spectral plot displays no high frequency data. This is also apparent in the waveform by the lack of noise riding on the 40 - Dust Filter Fa n No.2 C/Mill sinusoidal shape M72 92 -F1H Fan Inboa rd Horiz ontal
120 90

P -P Disp in Microns

60

ROU TE SPECTRU M 18- Apr-02 18:04 :29 OVERALL= 5.46 V- DG P-P = 94.2 7 LOAD = 10 0.0 RPM = 141 8. RPS = 23.6 3

30

0 0 80 60 40 20 0 -20 -40 -60 0 1 2 3 Rev olution Numbe r 4 5 30 60 Frequency in kCPM 90 120

Displacem ent in Microns

ROU TE WA VEFOR M 18- Apr-02 18:04 :29 P-P = 87.3 8 PK (+) = 55 .85 PK (-) = 54 .21 CR ESTF= 1.81

Phase - Amplitude Characteristics

Velocity

Viewing the same data linearly across the spectra displays high and low frequency data that was not apparent with Displacement. The waveform displays an underlying sinusoidal waveform, but is carrying the high frequency data as well - noisier waveform
RMS V eloc ity in m m /S ec
7 6 5 4 3 2 1 0 0 20 15 10 5 0 -5 -10 -15 0 1 2 3 Rev olution Numbe r 4 5 30 60 Frequency in kCPM ROU TE WA VEFOR M 18- Apr-02 18:04 :29 RMS = 4.8 4 PK (+) = 15 .15 PK (-) = 12 .86 CR ESTF= 3.13 90 120 40 - Dust Filter Fa n No.2 C/Mill M72 92 -F1H Fan Inboa rd Horiz ontal ROU TE SPECTRU M 18- Apr-02 18:04 :29 OVERALL= 5.46 V- DG RMS = 5.4 4 LOAD = 10 0.0 RPM = 141 8. RPS = 23.6 3

V elocity in m m /S e c

Phase - Amplitude Characteristics

Acceleration
The spectra displays a lot of high frequency data, raised noise floor level. Waveform displays very distinct Filter Fa n No.2 C/Mill common to the high frequency impacting, 40 - Dust M72 92 -F1H Fan Inboa rd Horiz ontal data 0.7
RMS Acce leration in G-s
0.6 0.5 0.4 0.3 0.2 0.1 0 0 8 6 30 60 Frequency in kCPM ROU TE WA VEFOR M 18- Apr-02 18:04 :29 RMS = 1.5 5 PK (+) = 6.6 4 PK (-) = 5.9 6 CR ESTF= 4.29 90 120

Amplitude units also effect phase readings

ROU TE SPECTRU M 18- Apr-02 18:04 :29 OVERALL= 5.46 V- DG RMS = 1.5 0 LOAD = 10 0.0 RPM = 141 8. RPS = 23.6 3

Acc eleration in G-s

4 2 0 -2 -4 -6 -8 0 1 2 3 Rev olution Numbe r 4 5

Limitations

There are a few disadvantages to using Single Channel Phase analysis:

You have to have direct line of sight from the tachometer to the shaft (which is not always possible) Reflective tape needs to be on the shaft (This becomes a problem if the machine is running and no tape is fitted?) Direct sunlight or excessive vibration can cause error between the tachometer reading and the analyzer.

Where to take Readings

Before we take any phase data it is important to understand why we would want to collect phase data, and what can it tell us?
Phase data is a diagnostic tool and is most commonly used to confirm a suspect fault, such as:
Imbalance Misalignment

Looseness
Resonance In Phase (0)- Meaning the relationship between the two points are moving uniformly in the same direction. Out of Phase (180) - Meaning the relationship between the two points are moving in different directions

Common terminology used when analyzing phase data are:

Where to take Readings

We need to acquire phase data in a methodical way to enable us to distinguish certain fault types, (which will be discussed in other topics) When taking phase data, there is a lot of information we need to remember (amplitudes, in or out of phase and phase angle). To make things easier there is a simple method to follow:
Starting with the Driver take and end-end Vertical Phase reading. Note down the Phase and Amplitude results

Next take an end-end Horizontal Phase reading. Again note down the phase and amplitude results

Precautions!

There are a few precautions to consider when collecting and analyzing phase data. These are:

1) Transducer Direction
2) Observation Errors

Transducer Direction!
The orientation of a transducer is very important and is the most common cause of interpretation error (more common in the axial direction) 180

Data taken across a coupling shows 180 phase difference.

Are these in or out of phase?

Phase - Transducer Polarity

The selection of different amplitude units is just one source of hardware induced phase shifts. Another source of induced phase shift is Transducer Polarity This is to do with the internal wiring of the transducer.
Two identical transducers can be wired the opposite way round to each other causing a 180 phase shift between readings. (Only associated with Cross Channel Phase

AB

Place the two transducers side by side and acquire a phase reading. The phase angle should be 0 if it is 180 then this should be deducted from all phase readings thereafter

Phase Summary

It is important to understand phase as it is a useful tool for doing Investigative vibration analysis. Phase data is a useful tool for finding many common machine faults
Imbalance Misalignment

Looseness / Soft Foot

It also helps the analyst to visualise the actual movement of the machine
Like a basic ODS.

Be careful of Transducer Polarity and Transducer Direction as each can effect the phase angle Allow a 30 tolerance across all phase data

Vibration Characteristics

Amplitude Frequency
Phase Direction

Vibration Direction

Vibration is measured in three direction

Horizontal Vertical Axial

Measurement Points
OB Motor M1H M1V M1A M2H M2V M2A P1H P1V P1A IB IB Pump P2H P2V P2A OB

Vibration Spectrum

Fast Fourier Transform

The term FFT stands for Fast Fourier Transform

It is named after an 18th century mathematician called Jean Baptiste Joseph Fourier. He established:
Any periodic signal could be represented as a series of sines and cosines. Meaning if you take a time waveform and mathematically calculate the vibration frequency along with their amplitudes, we can convert this in to a more familiar frequency format.

Fast Fourier Transform

Complex waveform changes to a simple waveform

The waveform is converted to an amplitude/frequency domain

Amplitude Amplitude

T i m e
This is called a spectrum

T i m e

y n e u q e rc F

Amplitude

Spectrum

Before we learn how to diagnose potential faults within a spectrum, we need to understand the units of measurement. The vibration data that is converted from the waveform by the FFT process can be seen very clearly However there are a few considerations we need to take into account first.

The amplitude scale and the amplitude units are important

As well as the frequency scale and units

Energy in Spectrum

Synchronous Energy

Synchronous energy - related to turning speed.

We can see from the spectrum that the first peak is at 1 Orders (which means it is 1 x turning speed) All the other peaks are harmonics off, which means they are related to the first peak Examples of synchronous energy: 1) Imbalance 2) Misalignment

3) Gearmesh

Non- Synchronous Energy

Non-synchronous energy not related to turning speed

We can see from the spectrum that the first peak is at 10.24 Orders. This is not related to turning speed.

Examples of non-synchronous energy:

Bearings Multiples of belt frequency Other Machine Speeds

Sub-Synchronous Energy

Sub-synchronous energy Less than turning speed

The spectrum shows the first impacting peak below 1 Order. This is subsynchronous energy Examples of subsynchronous energy are: Belt Frequencies

Other Machine Speeds

Cage Frequencies

Lines of Resolution

Lines of Resolution (LOR) determine how clear the peaks(data) are defined within our spectrum. The more lines we have over the same F-max (Maximum frequency scale). The more accurate our data will be Example.
The diagram below shows data that has been collected using 400 LOR. Notice how the top of the peaks are capped. When the LOR are increased the data becomes more accurate.

Lines of Resolution
0.5 TA 16 L2 - TA 16 -M1H Motor Outboard H orizontal A nalyze Spectrum 13-Mar-01 09:13:53 PK = .7078 LOA D = 100.0 R PM = 1496. R PS = 24.94

0.4

The spectrum shown displays data at 800 L.O.R with an Fmax of 1600 Hz

PK A cce leration in G -s

0.3

0.2

0.1

0 0 400 800 Frequency in H z 1200 1600

Lines of Resolution
0.20 0.5

TA 16

L2 - TA 16 -M1H Motor Outboard H orizontal A nalyze Spectrum 09:14:16 13-Mar-01 09:13:53

PK = .3852 .7078 LOA D = 100.0 1497. R PM = 1496. 24.95 R PS = 24.94

0.16 0.4

The spectrum shown displays data at 800 L.O.R with an Fmax of 1600 Hz

PK A cce leration in G -s PK A cce leration in G -s

0.12 0.3

0.08 0.2

0.04 0.1

The second spectrum displays the same data but with 3200 L.O.R over the same Fmax

0 0 400
800 Frequency in H z

1200

1600

Lines of Resolution

There are 8 LOR settings we can choose from on the analyzer. These start at 100 Lines and go up to 6400 Lines.

The average number of LOR is around 800 Lines for a typical motor/pump set up

To change the LOR settings we need to alter our parameter set. This is done in the Database Setup program Remember. If you double your lines of resolution you double your data collection time.

Questions

3 mils
0.001

0.002

0.003

0.004

sec

CPM

3 mils
0.001

0.002

0.003
T=

0.004

sec
0.002

F=

1/T

F= F= F=

1/0.002 500 500 x 60 30000 Hz CPM CPM

6 Mils P-P

F=

60000

90000

CPM

3
In / sec
0.002

0.004

0.006

0.008

sec

CPM

3
In/sec
0.002

0.004

0.006

0.008

sec

In / sec Pk

60000

90000

CPM

2
Gs
0.003

0.006

0.009

0.012

sec

CPM

2
Gs
0.003

0.006

0.009

0.012

sec

Gs RMS

1.414

20000

30000

CPM

11

Bonus : if RPM = 1000 What type of Energy is this?

0.015 0.030 0.045 0.060

mils

sec
Bonus : if RPM = 3000, and Fmax = 50 x RPM, Using LOR = 1600, Calculate BW in CPM & Hz?

4.2

In/sec

0.01

0.02

0.03

0.04

sec

10

Bonus : if RPM = 3600 What type of Energy is this?

0.032 0.064 0.096 0.112

Gs

sec

3 mils
0.9
0.001

0.002

0.003

0.004

sec

CPM

3 mils
0.9
0.001

0.002

0.003

0.004

sec

Mils P-P

1.8
CPM

60000

90000

10 In / sec 4
0.005

0.010

0.015

0.020

sec

CPM

10 In / sec 4
0.005

0.010

0.015

0.020

sec

In / sec Pk

10

4
CPM

12000

18000

24000

100
Acceleration can be measured in which unit?
A: mm/sec C: Microns B: G-s D: Hz

200
The unit RMS or mm/sec can equate to which amplitude measurement?
A: Acceleration C: Velocity B: Displacement D: Peak to Peak

300
Displacement measures which value of a waveform?
A: Peak to Peak C: RMS B: Peak D: Average

500
What are the three units of Frequency?

A: Hz CPM RMS C: Peak Hz RMS

B: Hz CPM Peak
D: Hz CPM Order

1,000
The Peak value of a waveform relates to which amplitude measurement?
A: Velocity C: Average B: Displacement D: Acceleration

2000
What does Synchronous energy mean?

A: Below 1 Order C: Bearing Defect

B: Related to 1 Order D: Above 1 Order

4,000
What unit is best used to detect bearing defects?

A: Velocity C: Average

B: Displacement D: Acceleration

8,000
If a motor runs at 1500RPM how many orders would 4500 CPM be?
A: 1 Order C: 2.5 Orders B: 2 Orders D: 3 Orders

16,000
Sub Synchronous Data is?

A: Below 1 Order

B: Equal to 1 Order
D: Above 1 Order

C: Up to 5 Orders

32,000
A Spectrum is defined as: Amplitude versus ?
A: Time C: Frequency B: CPM
D: Hz

64,000
The measurement point P2P is taken where on the machine?
A: Inboard D/E C: Outboard ND/E B: Inboard ND/E
D: Outboard D/E

125,000
The measurement point F2A means?

A: Fan inboard axial C: Fan inboard vertical

B: Fan inboard peakvue D: Fan outboard axial

250,000
Locating turning speed will distinguish?

A: The Frequency Units C: The Amplitude Units

B: Peak Amplitudes
D: Synchronous Energy

500,000
Bearing Defects are?

A: Non Synchronous C: Undetectable

B: Synchronous D: Only Detectable with Peakvue

1,000,000
Electrical defects are what type of energy..?

A: Synchronous C: Undetectable

B: Sub Synchronous
D: Non Synchronous