Vibration Analysis Services

FES Systems Inc.

FES Systems Inc.

What is Vibration?

Vibration is the movement of a body about its reference position.

Vibration occurs because of an excitation force that causes motion.
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Vibration Terms

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Time Waveform Analysis

q.
re
f
h
hig

overall vibration

tim

e
low

fre

q.

y
nc
e
qu
fre

Individual vibration signals

combine to form a complex
time waveform showing overall
vibration

complex time waveform

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Overall Vibration
z The total vibration
energy measured
within a specific
frequency range.
includes a combination
of all vibration signals
within measured
frequency range
does not include
vibration signals outside
measured frequency
range
produces a numerical
value
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Amplitude vs. Frequency

Vibration amplitude indicates the severity of the problem.
Vibration frequency indicates the source of the problem.

amplitude

1X

2X

3X

4X

frequency
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Vibration- Measurable Characteristics

Velocity is the first derivative of displacement as a function of time, it is the rate
of change in displacement (the speed of the vibration).
Acceleration is the second derivative of displacement, it is the rate of change of
velocity (the change in speed of the vibration).

90

180

Acceleration

270

Velocity

360

Displacement

Time
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Scale Factors
When comparing overall vibration signals, it is
imperative that both signals be measured on the
same frequency range and with the same
scale factors. NOTE: RMS is .707 of peak.

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Measurements & Units

Displacement (Distance)
mils or micrometer, mm

Velocity (Speed - Rate of change of displcmt)

in/sec or mm/sec

Acceleration (Rate of change of velocity)

Gs or in/sec2 or mm/sec2

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Lines of Resolution

Frequency in CPM

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3570 CPM

Amplitude

3570 CPM

Amplitude

7200 CPM

7200 CPM

Individual Vertical Lines or Bins Located Adjacent to One Another

Along the Frequency Axis. Each Bin is used to Store Individual Amplitude
at a Specific Frequency Location.

Frequency in CPM

11

Accelerometers
Rugged Devices
Operate in Wide Frequency
Range (Near 0 to above 40 kHz)
Good High Frequency Response
Some Models Suitable For High
Temperature
Require Additional Electronics
(may be built into the sensor housing)

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Velocity Sensors
Often Measure Bearing
Housings or Machinery Casing
Vibration
Effective in Low to Mid
Frequency Range (10 Hz to
around 1,500 Hz)
Self Generating Devices

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Displacement Probe/Eddy Probe

Measure Relative
Distance Between
Two (2) Surfaces
Accurate Low
Frequency
Response

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Multi-Parameter Monitoring
Same Data in Velocity and Acceleration
- Model 32L S/N AB10099P
#2 West -C3H Compressor Inboard Horizontal

0.40

PK Velocity in In/Sec

0.24

0.16

Route Spectrum
06-Feb-01 14:02:05
OVR ALL= .6123 V-DG
PK = 8.19
LOAD = 100.0
RPM = 2990.
RPS = 49.83
Reference Env/Prf-Std

4
PK Acceleration in G-s

OVRALL= .6123 V-DG

PK = .6091
LOAD = 100.0
RPM = 2990.
RPS = 49.83
Reference Env/Prf-Std

0.32

FES Model 32L S/N AB10099P

#2 W est -C3H Compressor Inboard H orizontal

Route Spectrum
06-Feb-01 14:02:05

0.08

0
0

40

80

120
160
Frequency in kCPM

Velocity
Spectrum

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200

240

40

On the same bearing, low

freq. events (imbalance,
misalignment, etc.) show
best in the velocity
spectrum; while high freq.
events (bearing faults,
gearmesh) show best in the
acceleration spectrum

80

120
160
Frequency in kCPM

200

240

Acceleration
Spectrum

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Sensor Relationships
100
Displacement (mils)
10

Acceleration
(g's)

Amplitude
1.0
(mils, in/sec, gs)

Velocity (in/sec)

0.1
Common Machinery
Operating Range

1
0.01
10

100

1,000

10,000

Frequency (Hz)

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Resonance

typically 10% or greater

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Detection vs. Analysis

z

Detection
Alarm limits are established for each measurement.
When the measurements value exceeds its
programmed alarm limits, the predictive maintenance
software or data collector notifies the analyst of a
problem.

Analysis
Once detected, analyzing exceptional measurements
provides insight to the problem itself, and to its root
cause.

FES Systems Inc.

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Important Frequency Peaks

Rotational Speed or Even Multiples
Always present but excessive amplitude or multiple
harmonics can indicate a problem.
Electric motors always have frequency peaks at shaft
rotational speed and at line frequency i.e. 60 Hz.
Two pole motors will always display a 2X line frequency
peak.

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Important Frequency Peaks

Gas Pulsation Frequencies
Screw compressors - gas pulsation frequency(cpm) occurs at
[No. of lobes on male rotor] X [ rotational speed (RPM)]
Pumps or fans - fluid pulsation frequency(cpm) occurs at
[No. of vanes, lobes or blades] X [ rotational speed (RPM)]
Recip. Compressors - gas pulsation frequency (cpm) occurs
at [No. of pistons] x [ rotational speed (RPM)]
Harmonics or even multiples (2X and 3X) of gas pulsation
frequencies always present and are most noticeable on oil
separator vessels.
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FES Systems Inc.

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Setting Up the Measurement

z

Physical Considerations

Database Considerations

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Selecting the Machinery

Selecting Measurement Planes
Selecting Sensor Locations
Surface Preparation
Sensor Mounting Techniques

Parameters (multi-parameters)
Alarm Limits
Setting Fmax
Scale Factors
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Selecting the Machinery

Critical - If a failure or shutdown occurs,
production is stopped, or machine
performance creates an unsafe environment

Essential Spared - If a failure or

shutdown occurs, production is disrupted

Non Essential Spared - If a failure

or shutdown occurs, production loss is
inconvenienced, however, a spare unit can
be brought on-line, or a repair can bring the
production unit back on-line without
significant loss of production

FES Systems Inc.

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Thinking
Ahead
Walk Through
z Machinery Data
Sheets
z

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Measurement Planes
z

radial
vertical
horizontal

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axial

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Sensor Location
(qualifying and identifying)
Measurement POINT numbering
follows flow of power:
Motor Non-Driven End (NDE)
Motor Driven End (DE)
Compressor Driven End (DE)
Compressor Non-Driven End (NDE)

FES Systems Inc.

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Sensor Location

The accelerometer must be located over the bearing of interest. Avoid air gaps
in housings whenever possible. Air gaps will skew vibration readings.
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Sensor Location

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Mounting Methods

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Hand-held/Probe Mounting
Rapid and
convenient.
Subject to
many sources
of error.
Use only as a
last resort.

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FES Systems Inc.

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Types of Alarms
Overall Vibration Limits
z Spectral Enveloping
z Spectral Bands
z Phase Alarms
z

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FES Systems Inc.

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Acceptable Vibration Levels

Tables are published that show overall vibration levels as a
function of rotational speed or vibration frequency for the
purpose of determining whether vibration levels are acceptable.
As a general rule for compressors operating at 3600 RPM an
overall vibration level of 0.3 ips RMS would be cause for concern

For piping and valves overall readings exceeding 1.0 ips RMS
would be cause for concern though actual stress values induced
by the vibration may be quite low and no corrective action
needed. Some engineering evaluation should be conducted to
determine this.

FES Systems Inc.

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ISO Guidelines
ISO 2372
overall
velocity
vibration
guidelines

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velocity - in/sec (peak)

acceleration - Gs (peak)

Assessing
Overall
Vibration
Severity

Frequency - CPM
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Overall Vibration Trend Plot

VIB - Alignment Fault
ALIGNMENT -M1H MOTOR OUTBOARD BRG. - HORIZONTAL
Trend Display
of
FAULT
OVERALL VALUE

0.24

PK Velocity in In/Sec

0.20
0.16

-- Baseline -Value: .06350

Date: 11-AUG-95

0.12
0.08

ALERT
WARNING

0.04
0
0

FES Systems Inc.

100

200
300
400
Days: 11-AUG-95 To 11-DEC-96

500

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Spectral Enveloping
VIB - Balance Fault
BALANCE -M2A MOTOR INBOARD AXIAL

0.40

Route Spectrum
14-MAR-96 12:10:26

PK Velocity in In/Sec

0.35

OVRALL= .3260 V-DG

PK = .3257
LOAD = 100.0
RPM = 1777.
RPS = 29.62
Reference Envelope

0.30
0.25
0.20

alarm is triggered

0.15
0.10
0.05
0
0

FES Systems Inc.

400

800
1200
Frequency in Hz

1600

2000

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Phase Alarms
A2 - Machine #6 (Various Setups)
MACH#6 -PPH PEAK PHASE DATA
0

Correlation
Display
Phase
vs
Peak
Data Period:
26-Dec-96
To
28-Dec-96
2.500

90

270

180
Peak

FES Systems Inc.

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Acceptable Vibration Levels

Motor
and
compressors
with
sleeve
bearings
do not
lendlend
Motor
and
compressors
with
sleeve
bearings
do not
themselves
well
to to
readings
with
accelerometers
andand
for for
themselves
well
readings
with
accelerometers
dependable
information
a device
such
a proximity
probe
dependable
information
a device
such
as aasproximity
probe
should
used
measure
vibration
in mils
displacement.
should
bebe
used
to to
measure
vibration
in mils
displacement.
Probes should be oriented in two planes 90 apart and
Probes
should be oriented in two planes 90 apart and
displacement cannot exceed the shaft to bearing clearance.
displacement cannot exceed the shaft to bearing clearance.

FES Systems Inc.

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Acceptable Vibration Levels

For Individual spectrum peaks limits are set by their perceived
For Individual
peaks are
limits
are set
by their perceived
cause
but somespectrum
general limits
shown
below:
cause but some general limits are shown below:

Compressors:
Compressors:
Rotational
speed
1X,1X,
2X, 2X,
3X 3X 0.25 ips
RMS
Rotational
speed
0.25
ips RMS
Gas
Pulsation
at compressor
0.27 ips
RMS
Gas
Pulsation
at compr.
0.27
ips RMS
Bearing fault frequencies
0.15 ips RMS
Bearing
fault
frequencies
0.15 ips RMS
Roller bearings (2000-3000 Hz)
2.5 gs
Roller bearings (2000-3000 Hz)
2.5 gs

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Motors:Acceptable Vibration Levels

Rotational Speed 1X, 2X, 3X
0.25 ips RMS
Line
Frequency 1X, 2X
0.13 ips RMS
Motors:
Bearing
faultSpeed
frequencies
0.15
RMS
Rotational
1X, 2X, 3X
0.25
ipsips
RMS
Line Frequency 1X, 2X
Bearing fault frequencies

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0.13 ips RMS

0.15 ips RMS

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Readings-How Often?
At start up - Baseline
At start up - Baseline

Six
after start
startup
upunless
unlessaaproblem
problemis is
suspected.
After
Six months
months after
suspected.
After
that
year after
afterthat
thatunless
unlessaadeteriorating
deteriorating
thatevery
every66month
month to
to one
one year
trend
trendisisobserved.
observed.
At 25000
25000 hours
three
months
At
hours readings
readingsshould
shouldbebetaken
takenevery
every
three
months
extendthe
thetime
time before
before an
totoextend
an internal
internalinspection
inspectionisisrequired.
required.

Anytime
an unusual
unusualnoise
noiseororvibration
vibration
is
Anytime an
is noticed.
noticed.

FES Systems Inc.

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Spectrum Analysis Techniques

z
z

Collect Useful Information

Analyze

500 HP/3570 RPM

Motor

M1

M2

Model 23LE
C3

C4

C1

C2

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Spectrum Analysis Techniques

Some compressors have a combination of sleeve
bearings and ball thrust bearings that require different
analysis techniques.

FES Model GL Series Compressors

Thrust and
Sleeve
Bearing
Location

Sleeve Bearing Location

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Sleeve Bearing Wear Pattern

Latter stages of journal bearing wear are normally evidenced

by presence of whole series of running speed harmonics (up to
10 or 20). Wiped journal bearings often will allow high vertical
amplitudes compared to horizontal, but may show only one
pronounced peak at 1X RPM. Journal bearings with excessive
clearance may allow a minor unbalance and/or misalignment to
cause high vibration which would be much lower if bearing
Source: Technical Associates Inc.
clearances were set to specifications.
Illustrated Vibration Chart
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FES Systems Inc.

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Why Do Bearings Fail?

Inadequate Lubrication
- too much
- too little
- contaminated

Excessive Load
Caused by:
- misalignment
- imbalance
- bent shaft
- etc.....

Spall On Outer Race

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Improper Handling or
Installation
Age

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Typical Bearing Failure Rate

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Bearing Defect Frequencies

BPFO
Ball Pass Frequency Outer Race

BPFI
Ball Pass Frequency Inner Race

BSF
Ball Spin Frequency

FTF
Cage Frequency or
Fundamental Train Frequency

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Bearing Failure Stages

Stage 1

Stage 2

No apparent change on typical velocity spectrum

defects fund.
frequency range

defects harmonic
frequency range

Stage 3
Defects fundamental frequencies also appear
and may exhibit sidebands

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Defects harmonic frequencies appear

Stage 4
Defects harmonic frequencies develop multiple
sidebands (haystack), fundamental freqs. grow
and also develop sidebands

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Sidebands
VIB - Alignment Fault
ALIGNMENT -M2H MOTOR INBOARD BRG. - HORIZONTAL
Route Spectrum
01-AUG-96 15:15:26

RMS Acceleration in G-s

0.14
0.12

OVRALL= .0665 V-DG

RMS = .2506
LOAD = 100.0
RPM = 3606.
RPS = 60.10

0.10
0.08
0.06
0.04
0.02
0
0

FES Systems Inc.

1000

2000
Frequency in Hz

3000

4000

Freq: 2634.6
Ordr: 43.84
Spec: .02417
Dfrq: 120.19

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Harmonics

VIB - Alignment Fault

ALIGNMENT -M2H MOTOR INBOARD BRG. - HORIZONTAL
Route Spectrum
01-AUG-96 15:15:26

0.06

PK Velocity in In/Sec

0.05
OVRALL= .0665 V-DG
PK = .0660
LOAD = 100.0
RPM = 3606.
RPS = 60.10

0.04
0.03
0.02
0.01
0
0

FES Systems Inc.

1000

2000
Frequency in Hz

3000

4000

Freq: 57.69
Ordr: .960
Spec: .02572

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Waterfall Plot
VIB - Alignment Fault
ALIGNMENT -M2H MOTOR INBOARD BRG. - HORIZONTAL
0.05

PK Velocity in In/Sec

Max Amp
.0456
0
11-DEC-96
21-NOV-96
28-OCT-96
30-SEP-96
05-SEP-96

01-AUG-96
15:15:26
RPM= 3550.

01-AUG-96
0

FES Systems Inc.

1000

2000
Frequency in Hz

3000

4000

Freq: 57.69
Ordr: .975
Sp 1: .02589

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FES Systems Inc.

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Stator problems generate high vibration at 2X line frequency (2FL). Stator

eccentricity produces uneven stationary air gap between rotor and stator
which produces very directional vibration. Differential Air Gap should not
exceed 5% for induction motors and 10% for synchronous motors. Soft foot
and warped bases can produce an eccentric stator. Loose iron is due to
stator support weakness or looseness. Shorted stator laminations can cause
uneven, localized heating which can distort the stator itself. This produces
thermally-induced vibration which can significantly grow with operating time
causing stator distortion and static air gap problems.
Source: Technical Associates Inc.
Illustrated Vibration Chart

FES Systems Inc.

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Eccentric Rotors produce a rotating variable air gap between the rotor and
stator which induces pulsating vibration (normally between 2FL and closest
running speed harmonic). Often requires "zoom" spectrum to separate 2FL
and running speed harmonic. Eccentric rotors generate 2FL surrounded by
Pole Pass frequency sidebands (FP), as well as FP sidebands around running
speed. FP appears itself at low frequency (Pole Pass Frequency = Slip
Frequency X #Poles). Common values of FP range from about 20 to 120 CPM
(0.3 - 2.0 Hz). Soft foot or misalignment often induces a variable air gap due
to distortion (actually a mechanical problem; not electrical).
Source: Technical Associates Inc.
Illustrated Vibration Chart

FES Systems Inc.

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Broken or Cracked rotor bars or shorting rings; bad joints between

rotor bars and shorting rings; or shorted rotor laminations will
produce high 1X running speed vibration with pole pass frequency
sidebands (FP). In addition, these problems generate FP sidebands
around the second, third, fourth and fifth running speed
harmonics.
Source: Technical Associates Inc.
Illustrated Vibration Chart

FES Systems Inc.

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Loose or open rotor bars are indicated by 2X line frequency (2FL) sidebands
surrounding Rotor Bar Pass Frequency (RBPF) and/or its harmonics (RBPF =
Number of Bars X RPM). Often will cause high levels at 2X RBPF, with only a
small amplitude at 1X RBPF. Electrically induced arcing between loose rotor
bars and end rings will often show high levels at 2X RBPF (with 2FL
sidebands); but little or no increase in amplitudes at 1X RBPF.
Source: Technical Associates Inc.
Illustrated Vibration Chart

FES Systems Inc.

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Phasing problems due to loose or broken connectors can cause excessive

vibration at 2X Line Frequency (2FL) which will have sidebands around it
spaced at 1/3 Line Frequency (1/3 FL). Levels at 2FL can exceed 1.0 in/sec if
left uncorrected. This is particularly a problem if the defective connector is
only sporadically making contact. Loose or broken connectors must be
repaired to prevent catastrophic failure.
Source: Technical Associates Inc.
Illustrated Vibration Chart

FES Systems Inc.

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Dosk - RAM 700 HP Motor Test1

RAM TEST 1-M2L Mot. Inboard Horiz./2X Line Freq

0.40

Route Spectrum
10-Apr-01 08:20:35
OVRALL= .3045 V-DG
PK = .3028
LOAD = 100.0
RPM = 3579.
RPS = 59.64
Reference Env/Prf-Std

PK Velocity in In/Sec

0.32

0.24

0.16

0.08

0
0

8000

16000
Frequency in CPM

24000

Freq:
Ordr:
Spec:

7200.0
2.012
.283

The 2x Line frequency on this motor is .283 in/sec.

this indicates a stator eccentricity problem.
The spectrum was taken at 6400 lines of resolution.
FES Systems Inc.

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0.40

Dosk - RAM 700 HP Motor Test1

RAM TEST 1-M2L Mot. Inboard Horiz./2X Line Freq
Route Spectrum
10-Apr-01 08:20:35

0.32

PK Velocity in In/Sec

2 x Line Freq.

OVRALL= .3045 V-DG

PK = .2922
LOAD = 100.0
RPM = 3579.
RPS = 59.64
Reference Env/Prf-Std

0.24

0.16

0.08

7140 RPM
2x turning speed

0
6800

7000

7200
Frequency in CPM

7400

7600

Freq:
Ordr:
Spec:

7200.0
2.012
.283

The 2 x Line Frequency must be separated from 2 x turning speed

to determine rotor or stator problems. The data collector must be set
The
x Line F number of lines of resolution to separate these two frequencies
to a 2sufficient

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Vibration analysis can be used to determine rotor problems in motors.

The rotor bar pass frequency has penetrated the narrow band alarm.
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Vibration Analysis Services

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