Belt damage + Damaged area on belt moves through the pulley. + Time between pulses corresponds to belt rate ~./ frequency. git ‘ep! 0.1441 seconds = 0.23% = z = = Take action ae 1 Eel al aan I 5 =aStart with the machine * You should know what speed it is running at if you are controlling the test conditions! Cade [Warne [Elements Fane isis p jen Bett ROTATION O35 a3 Ta |1X MOTOR SHAFT 1 1 Tew" |1X BLOWER SHAFT (Yes 1 12163 M /2%MOTOR SHAFT No 2 2 BL BLOWER Loses Yer 2 2x8 SM 3xMOTOR SHAFT 3 3 28/2 BLOWER LOBES 4 4876 Set /3X BLOWER LOBES [Yes 6 714 4BL 4X BLOWER LOBES [Yes 3 37352 Mé~/MOTOR ROTOR BARS [No 6a ea Anything else? = There is a peak at 3.1X with a har * What could that be?Logarithmic scale Logarithmic scale LOGARITHIICWhat is a dB scale? + Amore convenient way to view logarithmic values. dB stands for “decibel”. In vibration: + 6 dB difference represents a 2X change + 12 dB change represents a 4X change + 18 dB change represents an 8X change v Van = 20Log.0 7 ep ¥ VealUSAl = 2010010 7-Fma7see v VealSl) = 201090 TF7se0 NOTE: The US. Navy and many American inves ue a zero dB rlrence of 10:8 msec, making esr reoxings 208 tiger tan mete 30 eas Logarithmic scale * Logarithmic scales: * Enable you to see low amplitude peaks in the presence of high amplitude peaks. * Enable you to see harmonics and sidebands that you may have missed. * Enable you to better see how the noise floor has been affected by the vibration.Logarithmic scale Logarithmic scaleLogarithmic scale * Try it sometimes: * You may be surprised what you see in the data. + If there are signs of bearing wear from envelope data (or PeakVue, Shock Pulse, Spike Energy, etc.) * If the base of peaks appear fat/broad. * If there are high amplitude peaks. * If you see small peaks. * If you suspect bearing faults, motor faults, resonance, etc. * To detect sidebands. Introducing the spectrum The “FFT” of the time waveform produces the spectrum. Time waveformChanging speed and frequency We can now see how the frequency changes in relation to the motor speed. Building the spectrum Now we continue the process to build the spectrum. This is the spectrum!Spectrum analysis Balance the machine soon + Start with the baseline measurement. 16 May 2006 is + Take another spectrum and see how it eee compares. 18 Apr 2006 + We can see that one fog peak is increasing in amplitude. 17 Mar 2006 + We can determine what po is wrong with the machine and assess the 415 Feb 2006 saveniviettpeenoeny ||[)) po lone noe: age emutors ogure coo aan player bet on your rma Ses eee el ae éo OD aw B & ~ 8 » & aw 3 2 » § on 38 ” 8 ww TI sew matin contin levers pao stonave nt Bi nintestptomopenten stewie [O]viron cous damage oveta2000wem.nentmnet< 2 ° Q 2 BN seu machine conaion Shorttarm operation alowable “unr BE untiitedtong.erm operation atowabie [EB] vinration eauses damage Mabie 2008 weanantainstnte Conditions that reduce equipment lifeDifferent types of f jure Petia reece err) one Acceptance testin; Emacs ISO Standards The following is a list of standards related to balancing and balance quality: 150 19802:1997 150 s0nna005 "50 191902007 constant ets tate art P pechcaten and venfcaen of balance tolerances Mestanical vbraton Mechanical bration Suceptiolty and sanity frmachines te unbalance Industral fen Specfeatins for balance quality and vont eve ectanicalvbrston Aslancing-Guleance onthe wie and application ofbalincing andaroS Acceptance testing: Industry guidelines + The GM standard is very clear and detailed: Acceptance testing: Industry guidelines + There can be no ambiguity. STANDARD MoTOR LINE AMPLITUDE ACCEPTANCE LIMITS 13 ware, |Au10734, a3) (005, saxo] sano 5 6 OSA5PM RUNNING SPEED (ORDERS) : STANDARD MOTOR-—-UTILITY OPERATIONS.Not a great challenge Introduction to balancing Unbalance exists where the geometric center and center of gravity are not the same.Let’s assume the red block represents the combined unbalance mass ~ the heavy spot. The goal of balancing is to add a weight of equal mass ‘at a position opposite the unbalance mass to counter-balance it. Let’s assume the red block represents the combined unbalance mass ~ the heavy spot. The goal of balancing is to add a weight of equal mass at a position opposite the unbalance mass to counter-balance it.Preparing for the balance job Balancing check-list 1. You can start and stop the machine? It is possible to add balance weights? It is possible to gain access to the rotor? Itis possible to control the speed of the machine? Will the speed, amplitude and phase be steady during the tests? aunwn It is possible to take a phase reading? 7. Do you have the required instrumentation and a balance program/method? Dynamic unbalance - two-plane balance Need to measure vibration from two bearings Need to measure phase.Tolerances and quality: Residual unbalance: ISO 1940 Tolerances and quality: Residual unbalance: API ‘The API standard provides an equation to calculate the allowable residual unbalance as described below ~notice there are no balance grades ~ it is one rule for all machines: ovis CELI Unbalance [U,..,J: 0z-in | Journal static load [W1: Ibs | Speed (N]: RPM. Combination: 1 Ly i Unbalance [U,,..]: gr-in | Journal static load [W]: Ibs | Speed [N]: RPM SET ‘Unbalance [U,...)° gr-mm | Journal static load [W]: kgs | Speed [N]: RPM ‘The AP! standard is equivalent to using a balance grade G of 0.67Tolerances and quality: Residual unbalance: MIL-STD-167A The US Navy also has a standard for balance quality. The current standards is MIL-STO- 167-1A:2005, which replaces the widely quoted MIL-STD-167 (SHIPS) 1974. Cn < 1500 RPM. G25 > 1000 RPM G10 Low noise G10 ® Fatigue causes 34% of bearing failures + “Parasitic” loads reduce life: Ly, = — ARPM " [ALOADY Handling & installation 16% Peery rdLubrication: 36%: Good lubricant + Fluid film 0.1 to 1 micron + Human hair: 60 microns = Dust particle: 25 micron + Finger print: 12 micron = Smallest particle you can see 40 microns + 1 Micron=1 millionth of a meter + 1 Micron= 0.039 mil False brinelling (operation, transport and storage)Vibration analysis methods Nes anit rad * Ultrasound and stress testing * Shock Pulse”, Spike Energy’, SEE“, PeakVue* amie cate * Enveloping and Amplitude demodulation * Acceleration spectrum Mid-low frequency : * Velocity spectrum * Time waveform analysis * Overalllevel vibration = & Motor and fan frequenciesMotor and fan frequencies 310 4h 42 5 ‘ 3 2 OT PITS OT EO WN WT 18DComplicated vibri + Apeak at the driving frequency (e.g. gearmesh) + Peaks on either side of that peak, separated by the modulation frequency (e.g. running speed) Gears Radial 0 47a 12° 6 20 28 28 323640 Orders, Complicated vibration: Modulation: Sidebands + Sidebands can take all sorts of forms + Lots of fault conditions generate sidebands: « Bearing, gearbox, motors, pump Sidebands of enter Frequency Dh aes aes Lee To Frequency (Orders)Topics to be covered The basics of vibration monitoring — how does vibration tell us about machine condition? Basic techniques: overall levels, HFD, spectrum + Complex vibration: Time waveform analysis + Understanding motion: Phase analysis and using a strobe | + Advanced topics: Enveloping, circle plots, autocorrelation S How can we utilize vibration? Ca. indication of the severity ‘+ Amplitude is important, but change in amplitude is more important zc. indication of the nature of the fault * Many tools are available to interpret the pattern An indication of the structural response * Use phase to learn more about the fault and check for resonanceAmplitude + Amplitude is important, but beware: + Amplitude depends on the measurement technique + We are more concerned with change in amplitude (and change in the pattern) Amplitude: Transmission path and mounting Bere Probe: 1135 Hz—0.35in/spkor 634 mm/srms Magnetic base: 1135 Hz ~ 0.16 in/s pk or 2.95 mm/s ms eee ) Adhesive mounting: 1135 He O44 n/epk or 235 mn/srmsUnderstanding the pattern + The pattern tells us about the nature of the fault + You have to decide how muchresolution you want Understanding the pattern + The pattern tells us about the nature of the fault + You have to decide how much resolution you want Amplitude,Understanding the pattern + The pattern tells us about the nature of the fault + You have to decide how much resolution you want Understanding the pattern + The pattern tells us about the nature of the fault + You have to decide how muchresolution you want i £is) Understanding the pattern + The pattern tells us about the nature of the fault + You have to decide how muchresolution you want i 5 “Ceoyrant © 2012 Mobis mata wen mobi com Understanding the pattern + The pattern tells us about the nature of the fault + You have to decide how much resolution you want i : ‘Copyiah ©2012 Mets nau ww mobs comUnderstanding the pattern Low frequency, mid frequency and high frequency Detail provided in a spectrum KE \etail provided in a time waveform (using time synchronous averaging and order tracking when necessary) = Detail provided by enveloping (HF techniques), orbits and* centerline plots Detail provided via circle plots, time synchronous averaging, autocorrelation and cepstrum plots KE Simple techniques + 1SO 10816-3 can be used to check velocity and displacement readings.Simple techniques + Trending of all the parameters gives you an indication of what is happening. Band alarms + The spectrum can be divided up into bands. Trends from those bands can be very informative.Motor and fan frequenciesMotor and fan frequenciesGearbox frequencies OPTI S OT ED OND UDOT ITN Ba Frequency (orders) Ski-slope + The time waveform can help you understand why the spectrum had a ski-slope.oi Cr adsl IK MM Worl Phase: Visualizing vibration + With many fault conditions, the spectral symptoms are similar; when you see 1X, 2X and 3X peaks, what are you going to do? + Phase can help you distinguish between: Unbalance (static, couple, dynamic, and overhung) Misalignment (belt and shaft) Eccentricity Bent shaft Cocked bearing Foundation flexibility Looseness Resonance(( Complicated vibratio mpacts: Harmonics + Multiple peaks in the spectrum at the key forcing frequency For example: + Running speed: Looseness + Bearing frequency: Wear, spall Harmonics ®> 1st Harmonic 2nd 3rd h 4 seh | {4 Go aeComplicated vibration: Modulation: Sidebands + Apeak at the driving frequency (e.g. gearmesh) + Peaks on either side of that peak, separated by the modulation frequency (e.g. running speed) Sidebands ee Center Frequency Sideband Frequency a o 1 2 3 « 5 6 7 8 9 10 (hee 207 wonton Frequency (Orders)Damaged inner race of a bearing Rotating looseness ee | TUEGear misalignmentVibration analysis: Enveloping + Filter-out the low-frequency, high amplitude vibration. “Rectify” the vibration signal Using low-pass filter to “envelop” the data View as a time waveform or spectrumVibration analysis: Enveloping + The spectrum will change in predictable ways 500 tkTime waveform analysis options: circle plot , Time waveform analysis options: circle plotBackground oe Thanks to digitization, a spectrum is a series of numbers. You do not have amplitude values atevery frequency. hall Sh le ect atBackground The resolution is therefore dictated by the Fmax and the “LOR” — the number of CPM or Hz between spectral values. Background For example: Fmax = 400 Hz and LOR = 400. Therefore: Resolution = 1 HzData collection goals — for spectra + Challenge three: Should we collect one spectrum that shows everything (i.e. all possible frequencies) or should we collect two measurements that use settings that highlight the unique parts of the spectrum? Measurement settings: Fmax The Fmax setting is very important in vibration analysis. The Fmax sets the highest frequency captured by the analyzer that will appear in the spectrum. Unfortunately, too many analysts choose default settings such as “1000 Hz”. The machine can generate high frequency vibration that is very important to capture. Unfortunately, as youincrease the Fmax you'seduce the actual resolution.Measurement settings: Fmax Measurement settings: Fmax Te When you increase the Fmax, 0.0625 you decrease the time it takes 200 0.25 40 to acquire the data. 500 0.625 16 4,000 1.25 os When you increase the Fmax, you decrease the resolution — LOR = 800 lines the same 800 numbers (in this example) are spread across the larger Fmax. 10,000 125 0.084 Fmax settings Ideal Fmax settings for different situations (a more generalized solution will be offered later): ‘Machines with rolling element bearings __-10xBPFI (or 100xRPM if 8PFI unknown) ‘Machines with journal bearings 20xRPM Gearboxes 3.25xGMEF (or 250xRPM if GMF unknown) Induction motors (special test) GxLF (high resolution e.g. 1600 fines) DC drives and VED 200,000 CPM (detect futing) & RPM = The turning speed of the machine BPFH = Ball Pass Frequency Inner race GMF = Gearmesh Frequency LF = Line frequency: S0Hz, 60Hz or VED specific Measurement settings: ResolutionMeasurement settings: Resolution re) When you inerease the LOR, you also increase the time it 400 25 04 takes to acquire the data and ‘200 125 08 it requires more memory. 1600062516 2m Sa a 1, More time at the machine, Fmax= 1090 He and more people required to test the same number of machines. 2. The analyzer may not have enough memory for the entire route. Measurement setting: wo spectra are better than one Two spectra, with different Fmax settings, ideally with different amplitude units, will provide the analyst with the best opportunity to see important features without additional work.Measurement settings: Suggested settings The following data collection settings are suggested as a good compromise between data collection time, speed of analysis, and capturing data once that will provide the analyst with all the data required. Low range (0-15X) velocity (in/sec or mm/sec) 1600 line spectrum High range (0-100X) acceleration (Gs or mm/s*) 800 line spectrum Long duration (100 shaft revolutions) time waveform Short duration (10 revolutions) time waveform Envelope, PeakVue or other “high frequency” measurements yeeye