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    Vibration Analysis For Improving Reliability

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    Devasyruc
    The document discusses vibration analysis for improving reliability in machinery. It covers topics like the basics of vibration theory, measuring vibration using FFT, and diagnosing machine faults from vibration spectra. Specific techniques discussed include condition monitoring, predictive maintenance using vibration data, and analyzing vibration signatures to identify issues like unbalance, misalignment, and mechanical looseness. The overall aim is to use vibration analysis to reliably detect problems in machines before failures occur.

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    Vibration Analysis For Improving Reliability

    Uploaded by

    Devasyruc
    235 views67 pages
    The document discusses vibration analysis for improving reliability in machinery. It covers topics like the basics of vibration theory, measuring vibration using FFT, and diagnosing machine faults from vibration spectra. Specific techniques discussed include condition monitoring, predictive maintenance using vibration data, and analyzing vibration signatures to identify issues like unbalance, misalignment, and mechanical looseness. The overall aim is to use vibration analysis to reliably detect problems in machines before failures occur.

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    Vibration Analysis for Improving Reliability - PPT

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    The document discusses vibration analysis for improving reliability in machinery. It covers topics like the basics of vibration theory, measuring vibration using FFT, and diagnosing machine faults from vibration spectra. Specific techniques discussed include condition monitoring, predictive maintenance using vibration data, and analyzing vibration signatures to identify issues like unbalance, misalignment, and mechanical looseness. The overall aim is to use vibration analysis to reliably detect problems in machines before failures occur.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    235 views67 pages

    Vibration Analysis For Improving Reliability

    Uploaded by

    Devasyruc
    The document discusses vibration analysis for improving reliability in machinery. It covers topics like the basics of vibration theory, measuring vibration using FFT, and diagnosing machine faults from vibration spectra. Specific techniques discussed include condition monitoring, predictive maintenance using vibration data, and analyzing vibration signatures to identify issues like unbalance, misalignment, and mechanical looseness. The overall aim is to use vibration analysis to reliably detect problems in machines before failures occur.

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    © All Rights Reserved
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    of 67
    At a glance
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    The key takeaways are that vibration analysis can be used to achieve reliability through condition monitoring techniques such as predictive maintenance. Vibration characteristics like frequency, amplitude and phase angle can help identify sources of vibration and machine faults.

    The different approaches to maintenance discussed are run-to-failure, preventive maintenance, predictive/condition based maintenance, and proactive maintenance.

    Vibration analysis is used to monitor the condition of machines and identify faults. Vibration characteristics provide physical insights into the frequency, severity, and cause of vibrations to pinpoint issues.

    Vibration Analysis for Improving Reliability

    Today’s Topics

    A. Achieving Reliability with the help of Condition Monitoring


    Techniques
    • Introduction to Vibration & It’s Theory
    • Characteristics of Vibration

    B. Measuring Vibration
    • FFT
    • Preparation for measurement
    • Data collection

    C. Diagnosis
    • Machine fault analysis
    • Interpretation of Spectrum
    Speaker
    • Name: N. Sampath Kumar
    • Designation: Head Technical, SPM
    Instrument India
    • Work Experience: 14 year of
    experience in condition
    monitoring
    • Education : B.E
    • Skills: Certified Vibration Analyst
    What is Reliable Plant

    Reliability: The ability of the machine to perform a required function


    under stated conditions for stated period of time.

    Reliable plant has machinery and equipment that operate at the


    desired level of performance and quality when called upon to operate,
    allowing the company to achieve its goals. Regular maintenance and
    checks can contribute to this.

    Reliable plant is clean, safe, well organized, efficient, dependable,


    stable, and competitive. As a result, a reliable plant will have happy
    customers, happy owners and shareholders, happy regulators and
    insurers, and happy employees. It is a safe and rewarding place to
    work.
    Significance Of Reliability

    What Do We Gain With Reliability?


    Availability
    Capacity
    Competitiveness
    Asset life
    Employee satisfaction
    Safety
    Compliance

    What Can Reliability Help Us?


    Cost
    Waste
    Environmental incidents
    Approaches

    1. Run to Failure
    2. Preventive maintenance
    3. Predictive/ condition based
    maintenance
    4. Pro-active maintenance
    Vibration World
    What is vibration?
    Basic Theory Of Vibration

    Simple Spring Mass System

    Max Acc
    Min Vel
    Upper
    Limit

    Displacement
    Max Vel
    Neutral Min Acc
    Position

    Lower
    Position
    Max Acc
    MinVel

    It follows sine curve.


    Significance Of Vibration Characteristics.

    Indicates Physical significance

    What is Vibrating? Why it is


    Frequency Identify the source of the Vibration.
    Vibrating?

    Amplitude How much is it Vibrating? Identify the severity of the problem.

    Phase Angle How is it Vibrating? Identify the cause of the Vibration.


    Physical Significance Of Vibration Amplitude

    Amplitude Indicates Units

    Displacement Total distance travelled by the mass Microns, Mils

    Velocity Rate of change of displacement. Mm/sec, Inch/sec

    Acceleration It is the rate of change of velocity. M/sec2, inch/sec2


    Vibration It is the response of a system to an
    internal or external force which
    causes the system to oscillate.
    ISO 10816

    2 - 1000 Hz
    Definitions of Amplitude

    RMS

    Peak

    Peak to Peak
    ISO Machine Class
    ISO 10816
    Vibration Severity Breakdown

    Vibration
    + 4 steps measurement
    (Shutdown)
    Effect repaires
    + 3 steps Report dangerous increase
    Plan major
    overhaul
    + 2 steps Report large increase
    Inspection,
    minor repairs
    + 1 step Report change

    Routine Maintenance
    Normal
    maintenance activities
    (lubrication, etc.)
    FFT Spectrum Plot

    FFT is a method of viewing the signal with


    respect to frequency
    Sine wave frequencies
    Pure sine wave

    seconds Hz

    2 sine waves

    seconds Hz

    Time domain Frequency domain


    Sine waves, complex motion
    Pure sine wave

    seconds
    Hz

    3 sine waves

    seconds
    Hz
    Complex motion

    seconds
    Hz
    From Time Record to Vibration Spectrum.

    Time record

    Sine waves
    FFT = Fast Fourier Transfer

    Vibration spectrum
    amplitude - frequency scale
    What is FFT?
    FFT mathematically converts overall complex signal into individual
    amplitudes at component frequencies.
    What is Vibration and Spectrum Analysis?

    Vibration analysis is a non-destructive technique which helps early


    detection of machine problems by measuring vibration.
    Collect useful information

     History of machine.
     Name plate details – RPM, Motor Rating, bearing no., number of
    gear teeth etc.
     Design operating parameters, critical speed.
     Control room data – Temperature, pressure etc.
    Common Direction Naming Conventions

    1. Horizontal Direction - A line drawn out from the machine shaft that runs
    exactly parallel to the ground.
    2. Vertical Direction - The shortest line possible connecting the machine
    shaft and the machine base/ perpendicular to the ground.
    3. Axial Direction - Runs along the axis of the machine's shaft (parallel to the
    shaft & ground). Vertical machines

    Horizontal: Parallel to discharge


    Vertical : Perpendicular to discharge
    Axial: Parallel to the shaft
    Measurement Location, Direction
    Do’s & Don’ts of Mounting Transducers
    Do’s & Don’ts of Mounting Transducers
    Do’s & Don’ts of Mounting Transducers
    Do’s & Don’ts of Mounting Transducers
    Do’s & Don’ts of Mounting Transducers
    Do’s & Don’ts of Mounting Transducers
    Precautions to be taken while collecting vibration data:
    Vibration Analysis
    Identifying Problems By Vibration Analysis

    • Unbalance (Static & Couple)


    • Misalignment (Angular, Parallel and Skew)
    • Eccentric Rotor and Bent Shaft
    • Mechanical Looseness, Structural Weakness and Soft Foot
    • Resonance and Beat Vibration
    • Mechanical Rubbing
    • Problems Of Belt Driven Machines
    • Journal Bearing Defects
    • Antifriction Bearing Defects. (Inner race, Outer race, Cage and Rolling
    Elements)
    • Hydrodynamic & Aerodynamic Forces (Blade Or Vane, Flow
    turbulence and Cavitation)
    • Gear Problems (Tooth wear, Tooth load and Gear eccentricity,
    Backlash, Gear misalignment, Cracked Or Broken Tooth)
    • Electrical Problems of AC & DC Motor (Variable Air Gap, Rotor Bar
    Defect)
    Unbalance and its Causes

    • Uneven distribution of mass


    • Dirt/ Dust accumulation
    • Machining errors
    • Uneven erosion and corrosion of impellers
    • Missing balance weights
    Types Of Unbalance

    • Static Unbalance

    • Couple Unbalance

    • Overhang Rotor Unbalance


    • High vibration in horizontal and vertical direction.
    • Amplitude increases as square of speed.
    • Dominant frequency at 1x rpm
    • Horizontal to vertical phase difference 900 on the same bearing housing
    • Correction: Static unbalance can be corrected with single correction
    weight in one plane of the rotor
    Unbalance Signature
    • High vibration in horizontal and axial directions
    • Dominant frequency at 1x rpm
    • 180 degree phase shift between both the bearings.
    • Correction: Couple unbalance requires two plane balancing.
    • High vibration in horizontal and axial directions
    • Dominant frequency at 1x rpm
    • 90 degree phase shift from vertical to horizontal.
    • Axial readings will be in phase.
    • Correction: Overhung rotor might be having both static and couple
    unbalance, each of which needs to be corrected.
    Misalignment

    Deviation of shaft position from its collinear axis of rotation


    Causes of Misalignment
    Types Of Misalignment

    Off set/ Parallel

    Angular

    Skew - Combination of offset & angular


     High Vibration in axial direction with 1x rpm
     There may be 1x rpm and 2xrpm in radial direction.
     Components (Motor and Pump) across the coupling will be 180 out of
    phase in axial and radial directions.
     High vibration in radial with 1x, 2x, and 3x rpm.
     2x rpm can be quite high compared to 1x rpm.
     Harmonics (3x-10x) generates as severity increases.
     If 2x rpm amplitude is more than 50% of 1x rpm then coupling damage starts.
     If 2x rpm amplitude is more than 150% of 1x rpm, then machine should be
    stopped for correction.
     Components (Motor and Pump) across the coupling will be 180 out of phase.
    Misalignment Signature
    • Predominant in 1x and there may be also be strong 2x and 3x rpm in
    axial direction.
    • 180 out of phase (top to bottom or side to side) in axial direction of
    same bearing housing.
    • Predominant in 1x and there may be strong 2x and 3x rpm in axial
    direction.
    • 180 out of phase (top to bottom or side to side) in axial direction of
    same bearing housing.
    Mechanical Looseness
    Types of Looseness

    • Structural frame/base looseness.

    • Loose pedestal bearing.

    • Rotating looseness - Loose bearing/improper fit between component


    parts.
    • Structural looseness will generate a strong 1x rpm in the direction of
    greatest weakness.
    • To distinguish looseness/unbalance, If 1x horizontal more than twice
    the amplitude of 1x vertical, looseness can be suspected.
    • 1800 out of phase in the vertical direction of two surfaces.
    • Look for 1x rpm and 2x rpm peak.
    • Some times 3x and sub harmonic peaks may also be present.
    • Phase will not be constant due to vibration motion generated.
    • Rotating looseness will generate a large number of harmonics and may
    cause the noise floor to raise.
    • Rotating looseness may generate “random” vibration so phase
    measurement will be erratic.
    • Bearing loose in the housing will generate 4x rpm peak.
    • Occurs when forcing frequency coincides with system natural frequency.
    • Strong peak at natural frequency. The base of the peak will also be elevated.
    • If you vary the machine speed, the vibration amplitude will change. If it moves closer
    (Increases) or further away (decreases) from natural frequency.
    • Phase will be 180 out of phase
    • Bump test is required to identify natural frequency.
    • ODS, modal analysis and bode test etc. can be used.
    • Requires changing of natural frequency or change of operating speed.
    • High gear mesh (number of teeth times running speed)
    • Its common to witness a peak at the gearmesh frequency. How ever if
    the amplitude of the peak increases, or harmonics develop, or the
    sidebands of the input or output speed grow in amplitude, then it is
    highly likely that a fault is developing in the gearbox.
    • Gear mesh= number of teeth x shaft speed
    • Output speed=Input speed x Input teeth/Output teeth.
    • 1x sidebands around the gearmesh frequency
    • Increase in amplitude of 1x sidebands around the gearmesh frequency
    peak.
    • The sideband will correspond to the speed of the gear that is eccentric.
    • The impact that results will excite the natural frequency of the gear.
    • We do not know this frequency, but when a peak raises with a broad
    base with 1x rpm side band, it is likely to be natural frequency of the
    gear.
    • Peak at vane pass or blade pass
    • All pumps, fans and compressors will normally have a peak in the
    spectrum at “blade pass” or “vane pass” frequency.
    • The amplitude of the peak may increase if the gap between the blades
    or vanes is not kept equal. It may also cause obstructions in discharge
    passage.
    • Vane pass= Number of vanes x rpm
    • Blade pass= Number of blades x rpm
    What is ESA?

    Electrical signature analysis is the procedure of acquiring the


    motor current and voltage signals, performing signal
    conditioning and analyzing the derived signals to identify the
    various faults.
    ESA Advantages

    • Non-intrusive, remote diagnostic technique


    • Complementary to vibration measurement
    - Torsional load fluctuations
    - Detect rotor problems
    • All types of electric machines
    - Motors and generators
    - AC and DC
    During actual operation, many harmonics will be present in the motor signal.
    This is know as the motor’s current signature. Analyzing these harmonics
    after amplification and signal conditioning will enable identification of the
    various motor faults.
    Faults Detected Using ESA

    • Broken rotor bar and end ring fault


    • Static eccentricity
    • Dynamic eccentricity
    • Stator mechanical faults
    • Stator electrical faults
    • Misalignment/unbalance
    • Defective bearings
    ENHANCING MACHINE RELIABILIY AND PLANT PRODUCTIVITY WITH
    COMPREHENSIVE CONDITION BASED MAINTENANCE SOLUTIONS

    S H O C K & V I B R AT I O N A N A LY S I S R E C I P R O C AT I N G M A C H I N E R Y A N A LY S I S

    O I L A N A LY S I S THERMOGRAPHY U LT R A S O U N D

    LASER ALIGNMENT BALANCING


    M O T O R C U R R E N T S I G N AT U R E A N A LY S I S

    M O T I O N A M P L I F I E D A N A LY S I S T R A I N I N G & C E R T I F I C AT I O N
    Thank you for your time

    To know more, please send and email to – [email protected]


    and also visit our website – www.spm.co.in

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