Balancing and Diagnostic Systems

Welcome to the seminar: Basics of vibration technology

Measurement & Analysis

Balancing and Diagnostic Systems

Lecturer :

Roland Kewitsch

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Vibration analysis increases knowledge

Provides necessary information for:
Evaluation of machine condition Recognition of on-going machine damage symptoms Identification of the cause and the damaged components Prognosis of remaining service life

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Machine damage in a power station

Total destruction of a generator

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Rolling-element bearing damage

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Diagnosis methods
Vibration measurement and analysis Displacement, expansion and process value measurement Temperature, speed and phase measurement Lubricant analysis (e.g. spectroscope, ferroscope, radionuclide) Optical examination (e.g. endoscope, microscope) Non-destructive testing (e.g. ultra-sound, X-rays)
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Vibration Measurement in the past (& still today)

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Diagnosis methods
Diagnosis by vibration measurement

Overall methods

Machine assessment using Overall measurements

=
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Diagnosis methods
Diagnosis by vibration measurement Analytical methods Overall methods

Machine assessment using Overall measurements

Fault identification using frequency analysis measurements

Dynamic behaviour analysis

With self-excitation methods

With external excitation methods

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Measuring machine condition in the past

The first portable vibration measuring instrument from the Schenck company
Demonstrated at an exhibition in Leipzig / Germany in 1925

Schenck was founded in 1881

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Modern machine diagnosis

Measuring machine condition with a modern measuring Instrument (VT-60)

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Measurement types for mechanical vibrations

Vibration displacement s
= deviation of measured point from rest position

in m or mil

Vibration velocity v
= velocity with which measured point moves about rest position

in mm/s or ips

Vibration acceleration a
= acceleration with which measured point moves about rest position

in m/s2 or g

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Characteristics of composite vibrations

Narrow-band examination - Extraction into harmonic components (e.g. using a frequency analyser or tracking filters) Broad-band examination - Through a summing formation in a defined frequency range (e.g. 10 . 1,000 Hz)

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Amplitude data for vibration measurement

so = speak = sm
Saverage

srms = seff
t

speak-peak = spp

su = speak = sm

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Composite vibrations
X

f
t

2f
t

+
X

f + 2f

=
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Vibration in Time Domain vs. Frequency Domain

x t
x t
1 2 3 4 5 6 7 8 9 10 11
1 2 3 4 5 6 7 8 9 10 11

x f

x t

f
1 2 3 4 5 6 7 8 9 10 1116

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Influence of integration - Practice

Vibration velocity spectrum

Vibration acceleration spectrum

Vibration displacement spectrum

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Selecting the measurement type

Vibration displacement:
Machines with speeds under approx. 600 rpm (10 Hz) Structural vibrations or Relative motions (shaft vibrations) in journal bearing machines of any speed

Vibration velocity:
Vibrations in machines with speeds above 600 rpm (10 1,000 Hz)

Vibration acceleration:
Vibrations with frequencies of interest above 2,000 Hz
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Vibration types in machines

Rotor Relative shaft vibrations Bearing casing Absolute bearing vibrations

Foundation
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Measuring Absolute Bearing Vibration

General rules:
Measurement points should be exactly defined and clearly marked Measuring points should be flat, clean and free of grease Loose paint and rusted surfaces should be cleaned or avoided Sensor must sit securely and not wobble Sensor and cable should not move during measurement
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Acceleration sensors

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Vibration velocity sensors

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Measuring Relative Shaft Vibration

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Eddy-current sensors
Discrete type:
Sensor with integral cable Calibrated extension cable Separate converter (oscillator)

Note: Cable lengths may not be altered!

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Eddy-current sensors
Integrated type:
Sensor with built-in oscillator and extension cable

Advice:
Cable can be extended up to 1,000m in length Use in temperatures above 110C is not possible

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Machine assessment using the Trend

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Machine assessment acc. to Standards and Guidelines

A number of important Standards and Guidelines for rotating masses have been replaced during the last years by:
DIN ISO 10816, parts 1 to 6 (absolute bearing vibrations) and DIN ISO 7919, parts 1 to 5 (relative shaft vibrations)

Reciprocating machines, including compressors, can be assessed according to

DIN ISO 10816-6 (Reciprocating machines with > 100 kW) DIN ISO 8528-9 (Reciprocating internal combustion machines)

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Assessment of an electric motor acc. to ISO 10816

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Assessment zones
Assessment zones according to DIN ISO 10816: Zone A:
Vibration in newly-installed machines

Zone B: Zone C: Zone D:

Machines may be operated for an unlimited time without restriction

Machines may be operated for a limited time

Vibrations are at a dangerous level and may cause damage to the machines
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DIN ISO 10816 Part 3, Group 2

Medium-sized machines with nominal power from 15 kW to 300 kW; Electrical machines with shaft height 160 mm H >315 mm

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Vibrations created in damaged bearings

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Impulses from a damaged bearing

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Damage frequencies in a rolling-element bearing

d n N Contact angle Rolling-element diameter No. of rolling elements Speed of shaft

Outer race damage Inner race damage Rolling-element damage Cage damage

fo = fi = fr = fc =

nN 2 60 nN 2 60 DN d 60 N 2 60

( 1 - d cos ) D (1+ d cos ) D

(1- d D

[ ] cos )
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( 1 - d cos ) D

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Damage frequencies in a rolling-element bearing

Ball-bearing SKF 6211 Dimensions D = 77.5 mm D = 14.3 mm n = 10 = 0 N = 3,000 rpm Damage frequencies Fo = N/60 4.1 = 205 Hz Fi = N/60 5.9 = 295 Hz Fr = N/60 5.2 = 260 Hz Fc = N/60 0.4 = 20 Hz

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BCU signal process

X

f
BCU

t t
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Trend observation
Example: Damage progress in a rolling-element bearing

Destruction

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