Vibration Fundamentals

Ijaz Naushad
Service Engineer
SUMICO Technologies (Pvt) Ltd
+92 321 4787883
[email protected]
www.sumico.com.pk
Basics of Vibration
Introduction:
‘What is Vibration?’
Objectives
 To understand:
– What is vibration ?
– How it travels ?
– Relationship between a waveform and a spectrum.
– Different units of measurement
– Three different forms of energy
– Understanding of Lines of Resolution
Principle of Vibration Analysis
 Mechanical faults generate Mechanical Defects detected
unique vibration with vibration analysis
Belt drive faults
– Geometry of the machine Imbalance
Misalignment
• diameter of the shaft, Bent shaft
Looseness
number of bearing Machine resonance
elements, etc. Cavitation
Shaft Rub
– Turning speed (e.g. RPM) Bearing Defects including:
•cage defect
•outer race defect
•inner race defect
•rolling element defect
Gear defects
Electrical faults
What is Vibration?

Question - What is Vibration?

 In simple terms vibration is :-

 ‘A response to some form of excitation’

 Vibration is the motion of a body about a

reference position caused by a force

 The free movement of the shaft in a

journal bearing will cause it to
vibrate when a ‘forcing function’ is
applied
How Does Vibration Travel
 Vibration transmits as a sine wave.
 We can measure this sine wave in an Amplitude versus Time
domain
 This is called a Time Waveform
Vibration from Mechanical Faults
Vibration from Mechanical Faults
Vibration from Mechanical Faults
Vibration from Mechanical Faults
Vibration from Mechanical Faults
Vibration from Mechanical Faults
Vibration Characteristics

• Amplitude How Much

• Frequency How Often
• Phase. When
How Does Vibration Travel
 Unfortunately there can be  We call this a complex sine
multiple sine waves emitting waveform
from a machine, So our
wave form becomes  Analysis is very difficult on this
complex type of waveform.
 Fortunately we have what’s
called an ‘FFT’ which converts
the complex waveform back
into several simple waveforms
 FFT Waveform - Spectrum
 The term ‘FFT’ stands for ‘Fast Fourier Transform’
 It is named after an 18th century mathematician called JBJ 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.
 Fortunately for us, the analyzer does it for us!
Signal Acquisition & Understanding the
Vibration Spectrum
Transducer Waveform

Amplitude
Overall
Energy Time

FFT
Amplitude Spectrum

Frequency
How the Vibration Spectrum is Created
FFT (Fast Fourier Transform)
Amplitude
Amplitude

Amplitude
cy
en
e qu
Tim Fr
e
Spectrums
Spectrums
 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
Amplitude Units

C1 - Example 4
E4 -MOH MOTOR OUTBOARD HORIZONTAL
0.5
Route Spectrum
09-Feb-00 12:41:33

OVRALL= .5785 V-DG

0.4 There are three different amplitude RMS = .5716
LOAD = 100.0
measurements we use, these are: RPM = 2937.
RPS = 48.95
Acceleration
RMS Velocity in mm/Sec

0.3

Velocity
Displacement
0.2

0.1

0
Freq: 2.937
0 20 40 60 80 100 120 140 160 Ordr: 1.000
Frequency in kCPM Spec: .01038
Amplitude Units
 Acceleration
– Measures the change in velocity over a period of time
 Velocity
– Rate of movement
 Displacement
– Measures total movement in relation to a reference point

 A good way of remembering this is to think of a car:

– From rest to 60mph is your acceleration (change in velocity over
time)
– Drive at 60mph for x-time (this is your velocity)
– From start to finish is the total distance traveled (Displacement)
Measuring Amplitude
 You can measure amplitude from a time waveform as shown:
0 to Peak

RMS
+

Average
Amplitude

Time ‘t’
-

Peak to Peak

 The period ‘t’ is the time required for one revolution of the shaft in this
illustration, which equals one cycle of the waveform
– During this period, the amplitude of the waveform reaches a positive (+)
peak, returns to rest, and reaches a negative (-) peak before returning to
rest
Measuring Amplitude
 Peak (Pk) – Amplitude measured from the ‘at rest’ position (0) to the
highest value (0 to Peak)
 Peak to Peak (Pk-Pk) – Amplitude measured from the peak positive (+)
value to the peak negative (-) value
 RMS (Root Mean Square) – obtained by averaging the square of the
signal level over a period of time and then taking the square root result
 Average (Avg) – Amplitude value that averages the peak values of the
waveform
0 to Peak

RMS

+
 You can calculate the different amplitudes Average

when one of the values are known:

Amplitude
Time
– RMS = 0.707 times the peak value ‘t’

– Avg = 0.637 times the peak value

-
– Pk-Pk = 2 times the peak value
Peak to
Peak
Amplitude Units
90 o 90 o

Time

Acceleration Velocity Displacement

English/Metric
Displacement Mils / μm Peak-to-Peak

Velocity In/Sec / mm/s Peak / RMS

Acceleration G’s /(mm/s2) RMS/Peak

1 mil = 0.001” =25.4 um
 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,
 Displacement - microns appears at 0.707 the value of
 Total movement, value is from the amplitude
Peak to Peak  Gives a good overall picture,
of the vibration in our machine
 Ignores all high frequencies and
looks at the low frequency
 What Effect Do These Have In Our
Spectrum

E6
19T - Example 6
-G3H GBox Shaft 2 Inboard Horz
 Velocity RMS
0.24
0.8
100
Route Spectrum

0.21
0.7
31-Jan-01 10:57:43
 Good overall value
OVRALL= 1.32 V-DG
80 RMS= =58.12
PK
P-P .6325
1.31
0.18
0.6
LOAD = 100.0
RPM = 1052.
 Acceleration G-s
RPS = 17.54
Accentuates the high
Microns


mm/Sec

0.15
0.5
PK Acceleration in G-s

60
frequencies
Velocity inin
Displacement

0.12
0.4

40
 Good for anti-friction
bearings & Gears)
RMS

0.09
0.3
P-P

0.06
0.2
20  Displacement -
0.03
0.1
microns
0
0 20000 40000 60000 80000 100000
 Accentuates the low
Label: Chipped Gear Tooth
Frequency in CPM frequencies
Monitoring Techniques
Vib Acceleration
accentuates HIGH frequencies,
and attenuates LOW frequencies.

Acceleration

Velocity
“flat” treats all frequencies equally.

Velocity

Displacement
accentuates LOW frequencies,
and attenuates HIGH frequencies.

Displacement

Freq
Frequency Units
 Frequency refers to how often something occurs:
– How often a shaft rotates?
– How often a rolling element hits a defected race?
 There are three ways to express frequency:
1. CPM – Cycles Per Minute
– 1CPM = 1RPM
2. Hz – Cycles Per Second
– CPM / 60
3. Orders – Multiples of Turning Speed
– Frequency/Turning Speed

 Consider a motor has a rotational speed of 1485RPM, in terms of frequency this

equates to:
– 1485 CPM (1rpm = 1cpm)
– 24.75 Hz (1485/60) (minutes to seconds)
– 1 Orders (1 x revolution of the shaft)
Energy in the Spectrum

C1 - Example 4
E4 -MOH MOTOR OUTBOARD HORIZONTAL
0.5
Route Spectrum
09-Feb-00 12:41:33

OVRALL= .5785 V-DG

0.4 RMS = .5716
LOAD = 100.0
RPM = 2937.
RPS = 48.95
RMS Velocity in mm/Sec

0.3

0.2

0.1

0
Freq: 2.937
0 20 40 60 80 100 120 140 160 Ordr: 1.000
Frequency in kCPM Spec: .01038
Non- Synchronous
Energy
Synchronous Energy
Sub-Synchronous
Energy
Energy in the Spectrum

C1 - Example 4
E4 -MOH MOTOR OUTBOARD HORIZONTAL
0.5
Route Spectrum
09-Feb-00 12:41:33

OVRALL= .5785 V-DG

0.4 RMS = .5716
LOAD = 100.0
RPM = 2937.
RPS = 48.95
RMS Velocity in mm/Sec

0.3

0.2

0.1

0
Freq: 2.937
0 20 40 60 80 100 120 140 160 Ordr: 1.000
Frequency in kCPM Spec: .01038
Synchronous Energy Los - Example 8
EX 8 -P2V Pump Outboard Vertical
1.0
Analyze Spectrum
15-Nov-95 10:00:16
 Synchronous energy - related RMS = 1.27

to turning speed. 0.8 LOAD = 100.0

RPM = 737.
RPS = 12.28

 We can see from the

RMS Velocity in mm/Sec

0.6

spectrum that the first peak

is at 1 Orders (which means 0.4

it is 1 x turning speed)
0.2
 All the other peaks are
harmonics off, which means
they are related to the first 0
Freq: 736.86
peak 0 6000 12000 18000
Frequency in CPM
24000 30000 Ordr: 1.000
Spec: .245
Label: Looseness

Examples of synchronous energy:

1) Imbalance 2) Misalignment 3)Looseness 4) Gears
Non-Synchronous Energy BF - Example 5
E5 -R4A ROLL BRG. #4 - AXIAL
2.0
Route Spectrum
12-Jul-96 17:16:42
 Non-synchronous energy - 1.8
OVRALL= 2.63 V-DG

not related to turning speed 1.6 RMS = 2.69

LOAD = 100.0
MPM = 3225.
1.4 RPM = 380.

RMS Velocity in mm/Sec

1.2
 We can see from the
spectrum that the first
1.0

peak is at 10.24 0.8

Orders. This is not 0.6

related to turning 0.4

speed. 0.2

0
Freq: 3888.9
0 6000 12000 18000 24000 30000 Ordr: 10.24
Frequency in CPM Spec: .748
Label: Outer Race Defect
Priority: 1

• 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 sub-
synchronous energy
 Examples of sub-synchronous
energy are:
 Belt Frequencies
 Other Machine Speeds
 Cage Frequencies
Energy in a Spectrum

 Synchronous
– NxRPM where N is an integer (phase locked)
 Sub-synchronous
– <1 x RPM
 Non-synchronous
– F x RPM where F is >1x RPM but not integer
Lines of Resolution
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
L2 - TA 16
TA16 -M1H Motor Outboard Horizontal
0.20
0.5
Analyze Spectrum
13-Mar-01 09:14:16
09:13:53

PK = .3852
.7078  The spectrum shown
0.16
0.4 LOAD = 100.0
RPM = 1497.
1496. displays data at 800 L.O.R
RPS = 24.95
24.94
with an Fmax of 1600 Hz
G-s
in G-s

0.12
0.3
Acceleration in
PK Acceleration

0.08
0.2
 The second spectrum
PK

displays the same data but

0.04
0.1 with 3200 L.O.R over the
same Fmax
0
0 400 800 1200 1600
Frequency in Hz
Lines of Resolution
 There are 8 LOR settings we can choose from on the analyzer.
These start at 100 Lines and go up to 12800 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.
Review of Objectives
 To understand:
– What vibration is.
– How it travels.
– Relationship between a waveform and a spectrum.
– Different units of measurement
– Three different forms of energy
– Understanding of Lines of Resolution
 Ask questions if your not sure?
Analysis Techniques
Measurement Point Identification
Locating Turning Speed
Measurement Points
 Identifying Measurement Points
 What is a Measurement Point?
 A measurement point is simply:
– A reference to a particular place/plain on the machine to be
monitored
 Why do we need them?
– This helps the analyst know what the machine is and where the data was
collected.
– Also helps to ensure the data is collected at the same point on the
machine every time to help with repeatability of data
 A measurement point is determined by three characters.
 Each character refers to a particular place on the machine being
monitored
– E.g. M1H is a typical measurement point
Identifying Measurement Points
 What does M1H tell us about the point where the
data was collected?
 The first letter refers to the ‘Type of Machine’ being
monitored
– M = Motor P = Pump G = Gearbox

 The second letter refers to the ‘Measurement Plain’ for the

data to be collected
– H = Horizontal V = Vertical A = Axial P = Peakvue

  We know the data was collected on a ‘motor’ in the

‘horizontal’ direction
Identifying Measurement Points
 The number refers to ‘which side of the machine’ the data was collected
– Numbers are either ‘Inboard’(Drive End) or ‘Outboard’(Non-drive
End)
 The diagram shows the
numbering sequence for a
motor/pump unit
– Taking each machine as a
separate unit
 Each shaft is split into two and
numbered in numerical order
– starting at the drive unit
1 2 1 2
(non-drive end) through to
the driven unit (non-drive
end)
 Identifying Measurement Points
 What does the measurement point ‘M1H’ mean?

 M = Motor 1 = Outboard H = Horizontal

 Where would the point M1H be on the diagram below?

M1H
 Identifying Measurement Points
 Using the same motor pump  Question 2
unit as previous,
– Where would the
– Where would the measurement point M2A be
measurement P2H be taken? taken?
– What does P2H translate to? – What does M2A translate to?

M2A
P2H
Pump Outboard Horizontal

Motor Inboard Axial

Identifying
Measurement Points
Point Identification Horizontal Mount Pump
M1V M2V M2A P1V P2V

M1H M2H P1H P2H

M1P M2P P1P P2P

P2A

P2A to be taken on first available flange on the pump casing

Point Identification Flange Mounted
Extended Shaft
M1V

M1P M1H

M2V

M2P M2H

M2A

No readings will be
taken on the bowl as
there is no direct
E transmission path.
N S

W
 Gearbox Point Identification
G5V G6V

G3V
G4V
M1V M2V G1V
M2A G2V

O/P
G6A

G4A

G2A

G6H

G6P
G4H
M1H
M2H G1H G2H G4P
M1P

M2P G1P G2P

Point Identification Horizontal Mount Fan
M1V M2V M2A
F1V F2V

F1H
M1H M2H F2H
F1P F2P
M1P M2P

F2A

F2A to be taken on first available flange on the fan bearing

Locating Turning
Speed
Turning Speed
 When performing analysis on spectrums and waveforms, it is of
utmost importance to set the turning speed (running speed) correctly

 When the turning speed has been located, the software will re-
calculate all the frequencies to this exact speed.

 Once the turning speed has been set, it is now possible to

determine what is Synchronous/Non-synchronous and Sub-
synchronous energy.
Turning Speed
 The spectrum is showing  By locating the turning speed, it
numerous impacts appearing at is very clear that the impacts are
different frequencies. Non-synchronous
BFI - Example 6
Ex6 -P2V PUMP OUTBOARD VERTICAL
12
Route Spectrum
30-Jan-96 15:14:51

10 OVRALL= 13.52 V-DG

RMS = 13.46
LOAD = 100.0
RPM = 2987.
RPS = 49.78
RMS Velocity in mm/Sec

0
Freq: 2.987
0 20 40 60 80 100 120 140 160 Ordr: 1.000
Frequency in kCPM Spec: .115
Analysis Techniques Test
 Have a look at the spectrum  When the turning speed
below. has been located
– Where was the data taken? – What type of energy is
present?
Los - Example 3
EX3 -P2V Pump Outboard Vertical
1.0
Analyze Spectrum
15-Nov-95 10:00:16

RMS = 1.27
0.8 LOAD = 100.0
RPM = 737.
RPS = 12.28
RMS Velocity in mm/Sec

0.6

P2V

Synchronous Energy
0.4

0.2

0
Freq: 736.86
0 6000 12000 18000 24000 30000 Ordr: 1.000
Frequency in CPM Spec: .245
 Review of Terminology!
 Acceleration (G-s)  Velocity (RMS)
– Change in velocity over time – Rate of movement
– Peak Value of the Waveform – RMS value within the waveform
– Accentuates high frequencies – Looks at both high and low
within the spectrum frequencies within the spectrum
 Orders
 Displacement (Microns)
– integer of shaft speed
– Total amount of movement
 CPM
– Peak to Peak value in the
– Cycles per Minute (1CPM = 1RPM)
waveform
 Hz
– Accentuates low frequencies
ignores high frequencies – Cycles per Second (1CPM / 60)
Introduction to Vibration

Data Collection
Transducers and Mounting Techniques
 Although there are many different types of transducers
available, the most common type used for day to day
data collection are Accelerometers.
 These transducers provide an electrical charge
proportional to acceleration by stressing piezoelectric
crystals typically 100mV/g sensors are used.
Sensor Mounting - Frequency Range
Stud
Mounting Mount
Pad
Flat
Magnet
Dual Rail
Sensitivity

Magnet

Hand
Probe

Freq
1.5KHz 10KHz 32KHz
Data Quality
 Whether it is your job to collect the data and/or analyse the
data it is important to understand that the technologies will
not give you the answer to a machines problem unless you
have collected meaningful, quality data

• There are certain considerations that must be taken prior

to any data being collected, these are:
– A good understanding of the internal make up of the machine, in
order to understand the best transmission path for data
collection - bearing locations, load zones etc.
– Ensure data is collected in a repeatable manner so we can
compare two or more readings to each other - trending purposes
– Variable speed machines - it is very important to collect data with
the correct running speed enter into the analyser
Transmission Path
• Damaged caused to a machine component will cause a
certain amount of vibration/sound or heat to propagate away
from the initial impact.
– It is the effect of the impact/force that we are trying to detect
• In many cases the further you are away from the initial
event the weaker the signal will become, resulting in the
data appearing to be lower in value.
– In more extreme cases the impact can be lost amongst other
machine noise by the time it has reached your transducer,
resulting in no detection of a machine problem.
• Usually the best place to acquire data from a machine, is at the
bearings.
– This is because the bearings are the only part of the machine that connect
the internal rotating components to the stationary components (Casing)
Repeatable Data
 Collect data in the same manner each time.
– This consistency will allow you to trend the machinery condition and properly judge the
progression of faults

 In order to aid with repeatable data the analyser requests

for data to be collected in certain locations on the
machine.
– These are called ‘Measurement Points’
Things to Remember about a Route
 A route includes information from one area only
 A route does not have to include all the equipment defined in that area
 The order of the equipment in the route can differ from that of the database
 Equipment can appear in more than one route BUT can not appear in the
same route twice
 Route measurement points may not include all the points configured on the
equipment
 Route measurement points do not have to be in the same order as they
appear in the database
 Data is not stored at the route level but in the database with the
measurement points, there for routes can be deleted but will not loose data
from the database
 A maximum of 50 routes can be stored to each area
 Each equipment has a maximum of 144 points
 And one route can only contain 1044 measurement points
 Important: A route file contains the equipment and measurement point ID’s and definitions / speeds. For this
reason the route does not recognise points if their ID’s are altered in the database
Frequency Bands

• Divide spectrum in frequency bands based on the

types of mechanical faults that might appear on the machine
Frequency Bands

• Divide spectrum in frequency bands based on the

types of mechanical faults that might appear on the machine

Imbalance
Frequency Bands

• Divide spectrum in frequency bands based on the

types of mechanical faults that might appear on the machine

Imbalance
Misalignment
Frequency Bands

• Divide spectrum in frequency bands based on the

types of mechanical faults that might appear on the machine

Imbalance
Misalignment
Looseness
Bearing Band 1
Bearing Band 2
Frequency Bands

• Divide spectrum in frequency bands based on the

types of mechanical faults that might appear on the machine

Imbalance
Misalignment
Looseness
Bearing Band 1
Frequency Bands

• Divide spectrum in frequency bands based on the

types of mechanical faults that might appear on the machine

Imbalance
Misalignment
Looseness
Bearing Band 1
Bearing Band 2