Training Program

On
Vibration Analysis
What Is Vibration?
It is the response of a
system to an internal or
external force which causes
the system to oscillate.
 What Is Vibration Analysis?

Vibration analysis
is a non-destructive
technique which
helps early
detection of machine
problems by
measuring vibration.
Basic Theory Of Vibration
Simple Spring Mass System

Max Acc
Mim Vel
Upper
Limit
Max Vel
Neutral Mim Acc
Position

Lower
Position Max Acc
Mim Vel

It follows sine curve.

 Frequency & Amplitude

Frequency:
How many times oscillation is occurring
for a given time period?
Units: CPS(Hz), CPM

Amplitude:
It is the magnitude of vibration signal.
Units: Micron, MM/Sec, M/Sec2
 Physical Significance Of Vibration
Characteristics

Frequency - What is vibrating?

Source of the vibration.

Amplitude - How much is it vibrating?

Size (severity) of the problem.

Phase Angle - How is it vibrating?

Cause of the vibration.
Frequency Measurement

60 RPM
= 1 Rev / s
= 1 Hz
 Amplitude Measurement

1. Displacement :
Total distance traveled by the mass.
Unit : Microns
2. Velocity :
Rate of change of displacement. It is the
measure of the speed at which the mass is
vibrating during its oscillation.
Unit : MM/Sec, Inch/sec
3. Acceleration :
It is the rate of change of velocity. The
greater the rate of change of velocity the
greater the forces (P=mf) on the machines.
Unit : M/Sec2, Inch/sec2
 A

B
C a
t

b
t

c
t
+

d
 Physical Significance Of Vibration
Amplitude

Displacement : Stress Indicator

Velocity : Fatigue Indicator

Acceleration : Force Indicator

 When To Use Disp., Vel. & Acc.?
VIBRATION
SENSITIVITY DISPLACEMENT

10

VELOCITY
.1

.01

.001
ACCELERATION

60 600 6000 60000 600 000

 What Is The Advantage Of Using
Velocity?

• Flat frequency range compared to

displacement & acceleration.
• Almost all machines generate fault
frequency between 600CPM to 60KCPM
• Velocity indicates fatigue.
• Velocity is the best indicator of
vibration severity.
 Scales Of Amplitude

Peak - a
Peak to Peak - 2a
RMS - 0.707 a
Average - 0.637 a
FFT Spectrum
Analysis
 What Is FFT?

• Known as Fast Fourier Transformation.

• Developed by J.B. Fourier in 1874.
FFT mathematically converts overall complex signal into
individual amplitudes at component frequencies
• Different machinery problems cause
vibration at different frequencies.

• Overall vibration coming out from machine

is combination of many vibration signals
form various machine parts and it’s
structure.

• FFT is a method of viewing the signal with

respect to frequency.
Pure sinus

t CPM

2 sine waves

t CPM
 Pure sinus
84
421

421
0 i 10 008
CPM

3 sine waves
1

008
CPM

Complex motion
95
221

1 02
0 i 20 134

CPM
 Spectrum
Analysis
Techniques
 Step - 1
Collect useful information

• History of machine.
• Control room data - speed, feed,
temperature, pressure etc.
• Name plate details - bearing no,
no of gear teeth etc.
• Design operating parameters,
critical speed.
 Step - 2 : Identify the type of
measurement procedure:
1. Identify measurement type-Disp, Vel, Acc.
Conversion Of Spectrums

Displacement - Microns
Speed - 2889 RPM

Velocity - mm/s

Acceleration - m/s2
2. Measurement direction - Hori, Vert, Axial.
 Step - 3
Analyze:

1. Evaluate overall vibration reading of the entire

machine.
(a) Identify 1x RPM peak.
(b) Locate highest amplitude.
(c) What is the direction of the highest amplitude?
(d) What is the frequency of the highest amplitude?
2. See the values of Shock pulse, HFD etc.
3. See the trend - in case of sudden increase the
problem severity increases.
4. Analyze the frequency for possible defects.
5. Analyze the phase readings for confirmation if
necessary.
 Manual
Vibration
Analysis
 Detection By Vibration Analysis
1. Unbalance(Static, Couple, Quasi-Static),
2. Misalignment(Angular, Parallel, Combination)
3. Eccentric Rotor, Bent Shaft
4. Mechanical Looseness, Structural Weakness, Soft Foot
5. Resonance, Beat Vibration
6. Mechanical Rubbing
7. Problems Of Belt Driven Machines
8. Journal Bearing Defects
9. Antifriction Bearing Defects
(Inner race, Outer race, Cage, Rolling Elements)
10.Hydrodynamic & Aerodynamic Forces
(Blade Or Vane, Flow turbulence, Cavitation)
11.Gear Problems (Tooth wear, Tooth load, Gear eccentricity,
Backlash, Gear misalignment, Cracked Or Broken Tooth)
12.Electrical Problems of AC & DC Motor ( Variable Air Gap,
Rotor Bar Defect, Problems of SCRs)
Unbalance
 Causes Of Unbalance
• Uneven distribution of mass of rotor.
• Dirt accumulation on fan rotors.
• Rotor eccentricity
• Roller deflection, especially in paper machines
• Machining errors
• Uneven erosion and corrosion of pump impellers
• Missing balance weights
 Types Of Unbalance

• Static Unbalance
• Couple Unbalance
• Overhang Rotor Unbalance
 Static Unbalance

Detection:
• Highest horizontal vibration
• Amplitude increases as square of speed.

• Dominant frequency at 1x rpm

• Horizontal readings reflect in vertical direction

also.
 Correction

Can be corrected by one balance weight

in one plane of rotor center of gravity.
 Couple Unbalance

Detection:
• High horizontal & axial vibration
• Dominant frequency at 1x RPM
 Correction

It requires two plane balancing

 Overhung Rotor Unbalance

Detection:
• High horizontal & axial vibration
• Dominant frequency at 1x RPM
 Correction

Overhung rotors might be having both

static and couple unbalance and each of
which requires correction.
Misalignment
 Causes Of Misalignment

•Thermal expansion - Most machines align cold.

•Machine vibrations.

•Forces transmitted to the machine by pipe or

support structure.

•Soft foot.

•Direct coupled machined are not properly aligned.

•Poor workmanship.
 Types Of Misalignment
1. Off set

2. Angular

3. Skew - Combination of
offset & angular
Diagnosis Of
Misalignment
 1.Vibration Spectrum Analysis:

Angular - Axial vibration at 1X RPM

Offset - Radial vibration at 2X or 3X RPM

Harmonics (3X-10X) generates as severity increases.

If the 2X amplitude more than 50% of 1X then

coupling damage starts.

If the 2X amplitude more than 150% of 1X then

machine should be stopped for correction.
SPM readings also high across the coupling.
 Misaligned Or Cocked Bearing

1. Predominant 1X & 2X in the axial direction.

2. SPM
Bent Shaft

Diagnosis:
1. High 1X axial and high 1X radial if bent is near the center.
2. High 2X axial and high 2X radial if bent is near the coupling.
3. Amplitude of 1X & 2X rpm will be steady.
4. SPM readings also high.
5. High bearing temperature.
 Eccentric Rotor

• When center of rotation is offset from geometric center.

• Dominant frequency 1X.
• Horizontal to Vertical phase difference either 00 or 1800
at the same bearing housing (Both indicate straight-line
motion).
 Resonance

• Occurs when forcing frequency coincides

with system natural frequency.
• Causes amplitude amplification which

results catastrophic failure.

• Requires changing of natural frequency

or change of operating speed.

• Bode plot is used to identify resonance.
 Beat Vibration

• It is the result of two closely spaced frequencies

going into and out of synchronization with one
another.
• The spectrum will show one peak pulsating up
and down.
• Low frequency vibration 5 to 100 CPM.
• Beat frequencies are not normally a problem

when the differences exceed 150 to 200 CPM.

Mechanical
Looseness
 Causes

• It alone can not create vibration but in

the influence of Unbalance,
Misalignment, Bearing problems it
amplify the amplitude.
• It should be corrected first.
 Types

1. Structural frame/base looseness (1X)

2. Cracked structure/bearing pedestal (2X)
3. Rotating looseness - Loose bearing/improper fit
between component parts. (Multiple)
 1. Structural frame/base looseness (1X)
Caused by-
1. Structural looseness/weakness of machine feet,
baseplate & concrete base.
2. Deteriorated grouting.
3. Deterioration of frame or base
4. Soft foot.
5. Loose holding down bolts.
 Analysis
•Dominant freq 1X. Similar to unbalance &
misalignment.
 2. Cracked structure/bearing pedestal (2X)

Caused by-
1. Crack in the structure or bearing pedestal.
2. Occasionally on some loose bearing housing bolts.
3. Loose bearing or improper component fit.

Analysis-
1. 2X RPM amplitude is > 150% of 1X RPM amplitude in
radial direction.
2. Amplitudes are somewhat erratic.
3. 2X RPM phase somewhat erratic.
 3. Rotating looseness

Caused by-
1. Loose rotor.
2. Bearing loose in the housing.
3. Bearing loose in the shaft.
4. Excessive bearing internal clearance.
 Analysis

1. Generates running speed harmonics up to 20X RPM.

2. Generates low amplitude frequencies of 1/2x (i.e. .5x, 1.5x, 2.5x…)
and 1/3 x also.
3. Presence of 1/2x will indicate more advanced looseness problems
like presence of rub. It indicate other problems like unbalance and
misalignment.
4. Phase measurement will be erratic.
5. Phase for loose rotor will vary from one measurement to next.
6. Bearing loose on the shaft will generate 1x RPM peak.
7. Bearing loose in the housing will generate 4x RPM peak.
Journal
Bearing
Oil Whirl

Cause: Excessive clearance and light radial loading.

This results in the oil film building up and forcing the
journal to migrate around in the bearing at less than
one-half RPM.
Oil whirl is a serious condition and needs to be corrected.
It can create metal to metal contact.
A symptom peculiar for journal bearings is oil whirl.
It shows up as a vibration of approx. 0.42-0.48 X RPM.
Oil whirl can be diagnosed by increasing the load which
will decrease the subsyncronous vibration.

0.45X
severe oil whirl will cause looseness

1X
2X

frequency
 Journal Looseness
(Rotating Looseness)
 Rotor Rub

• Spectra similar to mechanical looseness.

• It may be partial or full annular rub.

• Often excites one or more resonance's.

• It can excites high frequencies.

• Cascade diagram and shaft orbit are very

helpful in diagnosing rubs.
 Rolling
Element
Bearing
Bearing Failure Detection
Frequency calculation for Rolling element bearings

FTF = Fundamental Train Frequency

BSF = Ball Spin Frequency
BPFO = Ball Pass Frequency Outer race
BPFI = Ball Pass Frequency Inner race

d
FTF 1. 1 cos Φ RPM RPM = Shaft rotation
2 D
2 d = Rolling element diameter
D d
BSF 1 cos Φ RPM
2d D D = Pitch diameter

BPFO N FTF N = No. of rolling elements

Φ = Contact angle
BPFI N(RPM -FTF)
 Rolling element bearings
What do the bearing frequencies mean?

If:
FTF = 0.381 * RPM
BSF = 1.981 * RPM
BPFO = 3.047 * RPM
BPFI = 4.952 * RPM

During one shaft revolution:

The cage rotates 0.381 revolutions

The ball spins 1.981 revolutions
4.952 balls pass an inner race defect
3.047 balls pass an outer race defect
Gear Box
 Gear box

Z1
RPM1

RPM2

Z2

GMF (Gear Mesh Frequency)

Z1 .RPM1 = Z2 .RPM2
where Z = no. of teeth and RPM shaft speed
Mating gears produce only one ‘Gear Mesh Frequency’
 Gear Box Defects

• Tooth wear
• Gear eccentricity & backlash

• Gear misalignment

• Cracked or broken tooth

• Hunting tooth
 Gear box
1/Rps
Z.Rps
Z.Rps-Rps Z.Rps+Rps

Z.Rps-2 Rps Z.Rps+2 Rps

frequency time

Spur gear produce vibration in radial direction and

helical gear produce in radial & axial directions.
Sideband spacing reveals the defective gear or pinion.
All analysis should be done at maximum load.
 Normal Spectrum

•All peaks are of low amplitudes

•No natural frequency of gear excited
 Tooth Wear

•GMF may not change

•High amplitudes of side bands

•Presence of natural frequency of gear (fn)

 Gear Eccentricity & Backlash

•Excites GMF, fn & their side bands

•High amplitudes of side bands

•Sideband spacing reveals the defective

gear or pinion.
 Gear Misalignment

•Excitesharmonics of GMF with side bands

•Amplitudes 2GMF or 3GMF higher than 1GMF
 Cracked / Broken Tooth

•High amplitudes of 1x RPM of gear or pinion

•Excites gear natural frequency.
•Time waveform indicates spikes at 1/RPM of broken or cracked tooth.
•Amplitudes of impact spikes in time waveform will be higher than
that of 1xRPM in FFT.
 Hunting Tooth

1. Faults on both gear & pinion occured

during manufacturing.
2. Causes high vibration at low
frequencies (less than 600CPM)
3. Gear set emits growling sound.
 Hunting Tooth Frequency
It is the rate at which a tooth in one gear mates with a particular
tooth in the other gear.

For well designed gearboxes HTF is low.

HTF = GMF . (lowest common prime factor) /(Z1.Z2)

Ex:
Z1 = 63, Z2 = 12
Z1 = 63 = 7.3.3
Z2 = 12 = 3.2.2
lowest common prime factor = 3
HTF = GMF. 3 / (63.12) = GMF / 252
 Belt Drive
d D

BF (Belt Frequency) = Rps. π .D / L

BF is the rotational frequency of the belt. Worn or mismatched belts will

produce radial vibration at BF and its harmonics. 2.BF is often dominant
with 2 sheaves in the system. BF is a subsyncronous vibration (below 1X).

)2
L≈2C + 1.57(D+d)+(D−d
4C
Belt Drive Eccentric sheaves

force

Eccentric sheaves will generate strong 1X radial components.

A common condition.
Looks like unbalance, but shows at both sheaves.
Belt Drive Sheave misalignment

Off-set Angular

Axial vibrations at 1X and BF with harmonics.

 Fans
Fan Blade Pass Frequency = RPM x no. of fan blades
(FBPF)

Mainly radial vibrations

FBPF with 1X RPM sidebands.

Unbalanced horizontal or axial vibrations.

Inadequate blade clearance (at FBPF or RPM harmonics)

Uneven velocity distribution across fan inlet gives FBPF vibrations

 Pumps
Vibration signature depends upon operating condition.
pressure, temperature, speed, cavitation….

Centrifugal pumps
at Vane Pass Frequency = RPM . no. of impeller vanes
and harmonics.

Gear pumps
at Gear Mesh Frequency and 1X sidebands

Screw pumps
at thread rate = RPM . number of threads and its
harmonics.
Electrical
Motors
 AC Motors
Asyncronous AC motors
Running speed:

120 where p = number of poles

RPMsync = ⋅f
p f = line frequency

If no. of poles = 2.
The motor will have a sync. RPM of 3000

fs = RPMsync - where fs = slip frequency

RPM
 AC Motors

All electrical machines vibrates at 2 . line frequency.

The reasons are expanding and collapsing magnetic fields.

This vibration is normal (to a degree).

The amplitude is a measure of the quality of the construction.

 AC Motors
Coast Down Test

Vibration suddenly drops down after switching off the power

 AC Motors
Faults possible to detect with vibration analysis:
Rotor thermal bow
Air gap eccentricity
Loose rotor
Eccentric rotor
Loose windings

Necessary data:
No. of stator slots (SPF)
No. of rotor bars (RBPF)
Line frequency (LF)
Slip frequency (SF)
 AC Motors
Frequency analysis of input current

current clamp

In order to find 2 X slip sidebands around FL, a analyzer

with high resolution, and preferably zoom around 50 Hz
is needed.
 D.C. Motor

Faults possible to detect with vibration analysis:

•Broken field winding

•Bad SCRs
•Loose connections
•Loose or blown fuses
•Shorted control cards
 Identification

For 3 phase rectified D.C. motors

• Broken field winding, Bad SCRs, Loose connections

Peaks at 6.LF

• Loose or blown fuses, Shorted control cards

Peaks at 1.LF to 5.LF
 Synchronous time averaging
-suppresses vibrations not synchronous with the measured object.

Roll 2
RPM Sampling always starts at
VIB
’tacho signal’ from roll 1.
Roll 1

3 3

1X 2X 3X

1X 2X 3X

0
0
One measurement Average of 10 measurements
 Enveloping
Detects low amplitude high frequency repetitive
bearing or gear mesh defects.

These defects emit repetitive low energy impact

signals that are highly pulse shaped and of very
short duration. They generate harmonics in the
very high frequency ranges.

These techniques filter out low frequency

vibration energies and therefore isolate &
emphasize specific high frequency signals.
I