Introduction

Welcome to Level 3, Lesson 5 - Industrial Vibration Analysis

For Predictive Maintenance And Improved Reliability, part of
CTC’s free online vibration analysis training series.
We hope you enjoyed and benefitted from the previous course
and will continue to build your vibration analysis knowledge as
you progress through Level 3.

Industrial Vibration Analysis For Predictive Maintenance And Improved Reliability

is created and presented by CTC for complimentary educational use only. This
training presentation may not be edited or used for any other purpose without
express written consent from CTC.
Training
Objectives

Upon completion of this lesson, you will understand:

How industrial vibration analysis is used to identify, predict, and prevent failures
1
in rotating machinery in a variety of industrial environments.
Background
Industrial vibration analysis is a measurement tool used to identify, predict, and
prevent failures in rotating machinery.
Implementing vibration analysis on machines will:

Improve the reliability Lead to better machine Reduce downtime by

of machines efficiency eliminating mechanical or
electrical failures
Background
Vibration analysis programs are used throughout industries world-wide to:

Identify faults in Plan machinery Keep machinery functioning

machinery repairs for as long as possible without
failure
Industrial Vibration Analysis –
Typical Machinery
Industrial vibration analysis is often used on:

Motors Pumps Gear Boxes

Compressors Turbines Conveyors

Machines with
Rollers Engines Rotating Elements
Industrial
Vibration Analysis
The rotating elements of these specific machines
generate vibrations at specific frequencies that identify
the rotating elements.

The amplitude of the vibration indicates the performance

or quality of a machine.

An increase in vibration amplitude is a direct result of

failing rotational elements such as bearings or gears.

Based on machine speed, the rotational frequencies can

be calculated and compared to the measurements to
identify the failure mode.
Industrial
Vibration Sensors

Vibration analysis requires measurement

and analysis of rotating machines using
different vibration sensors, including:
Accelerometers
Velocity Transducers
Displacement Probes

Accelerometers are the most common

sensor used in industrial vibration
monitoring.
Industrial
Vibration Sensors
Accelerometers are case mounted using a
permanent bolt or a portable magnet to hold them in
place.

They will measure the vibration of the machine and

output a voltage or current proportional to the
vibration and relative to a ‘g’ level (unit of
gravitational pull).

This signal can also be integrated to provide

measured output of velocity (inches/second or
mm/second).
Industrial
Vibration Sensors

It is very important to choose the

correct accelerometer, cable,
connector, and mounting method for a
specific application.

This will provide quality measurements

and accurate vibration data for
identifying faults in rotating machinery.
Displacement
Probes
Sleeve bearing applications require displacement
probes to measure the actual movement of the
shaft inside the sleeve bearing.

These non-contact probes measure the vibration of

the shaft and the gap between the shaft and the
internal diameter of the bearing.

Using an eddy current process, these probes will

provide an output voltage proportional to
displacement (inches or mm).
Vibration Analysis –
What Faults Can Be Identified?

Machine out of balance Vane pass disturbances

There are several faults Machine out of alignment Recirculation and cavitation
in rotating machinery
that can be identified by Resonance Motor faults (motor & stator)

measuring and analyzing

Bent shafts Bearing failures
the vibrations generated
by a machine, including: Gear mesh disturbances Mechanical looseness

Blade pass disturbances Critical machine speeds

Dynamic
Vibration Analysis

The measurement and analysis of

dynamic vibration involves
accelerometers to measure the
vibration and a data collector or
dynamic signal analyzer to collect the
data.

Analysis is usually completed by a

technician or engineer trained in the
field of rotating machinery vibration.
Dynamic
Vibration Analysis

The analog voltage output of the

accelerometer, 100 mV/g, is measured
by the data collector and presented as
a time waveform and FFT (Fast Fourier
Transformer) for frequency
identification.
Dynamic
Vibration Analysis
The plots of amplitude vs. time (time
waveform) and amplitude vs. frequency (FFT)
are required for the trained technician or
engineer to analyze and determine the
machine fault.

Since each rotating element generates an

identifying frequency, analyzing the
frequency disturbances will identify the faulty
element.

Once the fault is identified, parts can be

ordered and repairs can be scheduled.
Dynamic
Vibration Analysis
Dynamic vibration analysis can also be accomplished in several different manners:

Portable sensors and Permanent sensors and Permanent sensors and

portable data collection portable data collection permanent data collection
following a predetermined following a predetermined that provides machinery
route of machinery route of machinery protection 24 hours per day,
measurements requirements 7 days per week, 52 weeks
per year
Process
Vibration Alarms
A recent development in the predictive maintenance and reliability
market is to leverage the investment already made in process control
systems (PLC, DCS, and SCADA).

This allows the operations, maintenance, and process control teams

to monitor and alarm vibration levels on critical machines.

Using a standard 4-20 mA output, the signal conditioners and

sensors provide a current output proportional to the overall value of
the machine vibration.

This is not a dynamic analog signal, and it cannot be used to analyze

the machine fault, but it can be used to alarm the machine and
indicate when vibration levels are too high.
Process
Vibration Alarms

When high vibrations are

measured by the process
control system, action can
be initiated to determine the
cause of the vibration or to
shut down the machine to
prevent damage or failure.
Methods For Achieving
Loop Power 4-20 mA Outputs
Method 1

A dynamic accelerometer with an analog output can be

connected to a signal conditioner

The signal conditioner provides signal conditioning and

a 4-20 mA current output proportional to the vibration

It offers several different frequency filters to alarm the

region of interest

The dynamic signal is also available for the trained

technician or engineer to analyze
Methods For Achieving
Loop Power 4-20 mA Outputs

Method 2

A loop power sensor with a direct 4-20 mA output can

also be used

This sensor does not require a signal conditioner, but

the frequency filters are limited to 10 – 1,000 Hz and
3 – 2,500 Hz
Methods For Achieving
Loop Power 4-20 mA Outputs

No matter what method you choose, standard 4-20 mA

outputs proportional to machine vibration are available
for process control.

This allows the factory to leverage typical process

control monitoring methods and alarm schemes.

Convenient alarms for critical machines!

Conclusion
Vibration analysis is not a new technology – the Piezo effect
and charge output of certain materials was discovered in
1880 by the Curies, and the first accelerometer was built in
1923.

Over the last 100 years, this technology has been refined for
today’s industrial market to provide fast and efficient
measurements of rotating machinery vibration.

Sensors are designed to withstand harsh industrial

environments and provide critical measurements year after
year.
Conclusion
Cables and connectors are constructed of the
most rugged materials available and provide
the critical link from the sensor to the data
collector.

Designed for all type of environments, the

proper cable and connector combination will
eliminate any concerns for data transfer.
Conclusion

Mounting hardware is available for a broad range of

applications.

Measurements are accomplished quickly with portable

magnet mounts or quick disconnects.

Permanent sensor installation can be accomplished with

epoxy, stud mounting, or an array of specialty mounts
designed for permanent applications.
Why Choose
CTC?
Superior durability Accuracy and performance

Industry’s best lead times Knowledgeable staff

Industry leading warranties

Connect With CTC
We look forward to hearing from you
FAILURE
18-20 mA

www.ctconline.com [email protected]

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Waveform
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(585) 924-5900