PresentedBy:

MichaelMiller
REMason

OperationalChallengesofToday
Ourtargetiszerounplanneddowntime
y

MaximizeEquipmentAvailability&Reliability
y

PlanALLMaintenance HOW?

Wearetryingtobecompetitivetodaywithaplant
thatistypicallymorethan40yearsold andso
areourcompetitors.
y

ExtendMachineryLife&Rebuilds

Wearerunningourequipmentbeyond itsdesign
capacity tohandlethevarietyofmaterialsthatwe
mustprocess
y

IncreasedthroughputwithoutRISKofmachinefailure?
Vibration Basics (Miller)

AnswerTheseToughQuestions...
Whatmaintenancedoesthemachineneedduringthe
nextplannedshutdown?
y

DoIhavetheparts,doIhavethepeople?

Cantheequipmentrunbeyondthenextscheduled
outage?
y

WhatworkcanIsafelyscheduleoutuntilthenext
shutdown?

Vibration Basics (Miller)

WhatisVibration?
y Vibration The
motionofabody
aboutareferencepoint
y Atitssimplest,
vibrationisdisplayed
asdisplacementover
time

Vibration Basics (Miller)

WhyUseVibrationAnalysis?
"Of all the parameters that can be
measured non-intrusively in
industry today, the one containing
the most information on machinery
health is the vibration signature."
Art Crawford
Acknowledged expert
in the field of
vibration analysis

Vibration Basics (Miller)

OverallVersusSpectrum
y Overallcanletyouknowthatthereisaproblem
y HeyFred,somethingiswrongwithyourcar!

y Spectrumscantellyouwhattheproblemis
y HeyFred,yourwaterpumpisbad!

Vibration Basics (Miller)

TheUnits
Displacement accentuates
thelowfrequencies Mils
Acceleration accentuates
thehigherfrequencies
(gs)
Velocity isconsistentacross
alargerrangeof
frequencies
Mostvibrationis
analyzedinVelocitysince
theenergylevelis
consistentthroughoutthe
frequencyrange.
Vibration Basics (Miller)

Howdowemeasurevibration?
y Threetypesofsensors
y Displacement,Velocity,Acceleration
y Signalprocessorofsometype(CSI2130)
y Localorportabledisplayforfieldanalysis
y Remote
y Softwareforviewingandstoringcollectedvibration
data

Vibration Basics (Miller)

DisplacementProbes
TypicalApplications
y Sleevebearings
y Mostturbineandlargemotor
drivenmachinery
y
y

Mainturbinegenerators
Boilerfeedwaterpumps

y ApplicationsinwhichXY dataisrequiredfor
measurementssuchas
y
y

ShaftcenterlinefromDCgapdata
Orbitsfromvibrationdata

y Notpracticalforbearingorgearanalysis
Vibration Basics (Miller)

ElectromagneticInduction

Vibration Basics (Miller)

10

VelocityPickup
y VelocitySensorApplication

y Mountedoncaseofmachineorshaft

riders
y Usedonsleeveandrollerbearings
dependingontheapplication
y Whenintegrationtodisplacementis
required
y Hitemperature
y

Upto900Forhigher
Vibration Basics (Miller)

11

TheoryofOperation Velocity
Pickups
y Mechanical
Movingcoil
y Selfpowered
y Directional

Bobbin

Vibration Basics (Miller)

Bobbin
Spring

Pole

S
Magnet

12

Accelerometer
y AccelerometerApplications
y Casemountedormagnetmounted
y PrimarilyRollerelementBearingsandGears
y Whenanalysisanddiagnosticsareimportant

Vibration Basics (Miller)

13

Accelerometer
Amplifier
Preload
Bolt

Insulator

Inertial
Mass

Conductive
Plate

Piezoelectric
Crystal

Insulator

Vibration Basics (Miller)

14

Amplitude

Amplitude

Amplitude

Tim
e

Tim
e

Vibration Basics (Miller)

y
nc
e
u
eq
r
F

15

SignalProcessing TheMystery
1.5

Amplitude

0.5

Turning Speed

-0.5

-1

Time

-1.5

Turning Speed Time Waveform

Vibration Basics (Miller)

16

SignalProcessing
1.5

Amplitude

0.5

Turning Speed

2x TS

-0.5

-1

-1.5

Time

Add twice turning speed vibration

Vibration Basics (Miller)

17

SignalProcessing
1.5

Amplitude

0.5

Turning Speed
0

2x TS
7x TS

-0.5

-1

-1.5

Time

Add blade pass vibration

Vibration Basics (Miller)

18

SignalProcessing
1.5

Amplitude

0.5

Turning Speed
2x TS

7x TS
Brg

-0.5

-1

-1.5

Time

Add Bearing Vibration

Vibration Basics (Miller)

19

SignalProcessing
Total Vibration
3

-1

-2

-3

Vibration Basics (Miller)

20

SignalProcessing breakdowncomplexwaveforminto
waveformcomponents
The Fast Fourier Transform (FFT) takes the complex waveform and
breaks it down into the component sine waves
3

1.5

0.5

FFT

-1

-0.5

-2

-1

-3

-1.5

The amplitudes for each sine wave is then plotted at the frequency of the
sine wave, creating the Spectrum
Vibration Basics (Miller)

21

SignalProcessing TheFFTorSpectrum
Spectrum (FFT)
1.4

Twice
Turning
Speed

1.2

Turning
Speed

0.8

0.6

Blade
Pass
0.4

Bearing
Frequency
0.2

397

386

375

364

353

342

331

320

309

298

287

276

265

254

243

232

221

210

199

188

177

166

155

144

133

122

111

89

100

78

67

56

45

34

23

0
12

Amplitude

Frequency
Vibration Basics (Miller)

22

SoWhatcanVibrationAnalysisDetect?
y DetectandTrackprogressingstagesofBearingFailure
y IdentifyImbalance andMisalignment
y VibrationAnalysisisusedtocorrectImbalance

y Identify/correctResonance
y IdentifyMechanicalWear incouplings,bearings,support

structures,etc.
y Detectotherdefectssuchas:
y Lubefailure/softfoot/brokenrotorbars
y Pumpcavitation,andmanymore

Vibration Basics (Miller)

23

WhatisaVibrationProgram?
y Expertise,Technology,andWorkProcessesthat
y

PreventUnexpectedDowntime
y

ExtendMachineLifeandOptimizePerformance
y

Byassuringmachinesdonotfailcatastrophically

Bydetecting&correctingrootcauseconditionsthatcause
excessivewear
Do the right work

AllowYouToWorkEfficiently
y
y

At the right time

With the right methods

Bytrendingprogressingfaultsand
Coordinatingrepairstooccuratplannedoutages

Vibration Basics (Miller)

24

AFewCaseHistoriestoGetYouThinking
y PaperMill:
y

Onlinevibrationmonitoringdetectedacrackedshaft
y
y
y

Presssection
Trendincreaseddrasticallyover36hourperiod
Wouldhaveotherwisefailedcatastrophically

y OffshoreOilPlatform:
y

Onlinevibrationmonitoringsavescompressortwice!
y
y
y

Bearingproblemdetectedthroughvibrationanalysis.
Bearingwasreplaced.
Newfaultdetected6hourslater
y

Thermalexpansioncreatedbearingmisalignment

Vibration Basics (Miller)

25

A FewCaseHistoriestoGetYouThinking
CementMill:
Onlinevibrationmonitoringsolvesmystery
Airhandlerwithintermittenthighvibration
Resonanceoccurswhenbaffleopenat~61%.

PowerPlant:
Onlinevibrationextendsmaintenanceintervals
Preventiveturbinemaintenanceevery5years
Unnecessarymaintenancecaninducefaults!
Extendfrom6 10yearswithonlinemonitoring
Averagerepaircostaround$1million

Vibration Basics (Miller)

26

WhereShouldVibrationAnalysisbeUsed?
Plant Equipment

y Predictive
y Criticaltoproduction
y Preventive
y Supportequipment
y Reactive
y Easy/Inexpensivetoreplace

Vibration Basics (Miller)

27

EstablishingaVibrationProgram
y
y
y
y
y
y
y

Defineprogramfocus/resources
Determinecollectionmethod(s)
Createdatabase
Collectdata
Detectdevelopingfaults
Diagnosenatureandextentoffault
Documentbusinessandmaintenanceimplications

Vibration Basics (Miller)

28

1)DefineProgramFocus
y IdentifyCriticalMachines
y Effectonproduction
y Availabilityofbackupmachine
y Costtorepair
y Timetorepair
y DetermineResources
y Fullyinhousestaffed
y Fullyoutsourced
y Combination:Startup,Initialcontractservice,etc.

Vibration Basics (Miller)

29

2)DetermineCollection Method(s)
y Routebasedperiodic
y Onlinemonitoring
y Generalplant
y Criticalequipment
equipment
y Installedsensors
y Walkaroundsurvey
y Automaticmonitoring
y Manualmeasurement
y Definemeasurement
y Monthlyreadingtypical
interval
y Readilyaccessible
y Inaccessibleor
hazardousareas

Vibration Basics (Miller)

30

3)CreateDatabase
y Entermachineconfigurationinformation
y MachineID(assetcode)andDescription
y MachineDesigninfo,OperatingSpeed,etc.
y Definemeasurementpoints
PointID(identification)andDescription
y SensorType(accelerometer)
y AnalysisParameters(howtoanalyzesignal)
y AlarmLimits(allowableamountofvibration)
y

Vibration Basics (Miller)

31

DataCollectionPoints Nomenclature
MOH
MOP
MOV

MIH
MIP
MIV

PIH
PIP
PIV

POH
POP
POV

POA
MOA

Standard: 2 vibration directions per bearing + 1 axial per shaft

Add 1 PeakVue point per anti-friction bearing
MOH = Motor Outboard Horizontal
Vibration Basics (Miller)

32

CollectData(Survey)
1) Periodicsurveywith
walkaroundPortable
Analyzer

2)Continuoussurveywith
onlinemonitoring

Vibration Basics (Miller)

33

5)DetectDevelopingFaults
Visual detection using
color and shape

Vibration
divided
into
frequency
bands

Entire machine train

on one screen

Motor

Gearbox

Vibration Basics (Miller)

Pump
34

6)DiagnoseNatureofFault
y Eachmachinefaultgeneratesaspecificvibration
pattern(Bearings,Belts,etc.)
y Asinglevibrationmeasurementprovides
informationaboutmultiplecomponents
y Thefrequencyofthevibrationisdeterminedby
themachinedesignandoperatingspeed

Vibration Basics (Miller)

35

6)DiagnoseNatureofFault
Knowingtheaccurate
machinespeedand
phaseisimportant for
vibrationanalysis.

Atachometerisrequiredtodeterminemachinespeed
andphase.

Vibration Basics (Miller)

36

6)DiagnoseNatureofFault
Trend shows rate of
advancement
for fault in question

Vibration Basics (Miller)

Individual trend
parameter covers
suspect frequency
range

37

SubHarmonic 1X

Bearing Bearing

Gears

Bearing

Amplitude

2X

1x

50x
Trend of
Bearings

2x

Trend of
Balance
5
mm/sec
Time
(Days)

1
mm/sec

Alarm
Time
(Days)

Alert and Fault alarms for each parameter

Vibration Basics (Miller)

38

6)DiagnoseNatureofFault
Imbalance typically appears at the
turning speed of the machine

Imbalance

Vibration Basics (Miller)

39

6)DiagnoseNatureofFault
Misalignment typically shows up at
either 1 or 2 x turning speed

Misalignment

Vibration Basics (Miller)

40

6)DiagnoseNatureofFault
Looseness shows up as
multiples of turning speed

Looseness

Vibration Basics (Miller)

41

6)DiagnoseNatureofFault
Bearing wear shows up at specific peaks
related to the geometry of the bearing
and the speed of the shaft.

Bearing Wear

Vibration Basics (Miller)

42

RollerBearingFaults
Fourdifferentbearingfrequencies
Ball Spin Frequency
(BSF)
Fundamental Train
Frequency
(FTF)
Ball Pass Frequency
Inner Race
(BPFI)
Ball Pass Frequency
Outer Race
(BPFO)

Vibration Basics (Miller)

43

Specific peaks typically correlate to

Specific machine faults
Related to machine speed

Need Spectrum Analyzer for diagnostics, not just Overall vibration meter
Vibration Basics (Miller)

44

Advanced bearing wear shows up

clearly in spectrum

Vibration Basics (Miller)

45

Early bearing wear frequently sometimes cant

be detected with standard vibration
measurements.

Vibration Basics (Miller)

46

Sidebands
increase with
gear wear

Many distinct peaks

Gear Wear

Vibration Basics (Miller)

47

ExamplesofOrbits
Misalignment,
Resonance, Wear

Misalignment
Ellipse

Truncation

Shaft rub or
mechanical looseness

Misalignment
Banana

Inside ellipse

Sub-synchronous whirl

Misalignment
and other problems
Figure Eight

Vibration Basics (Miller)

Inner loop

48

7) DocumentBusiness
&MaintenanceImplications

y Document:
y Diagnoses
y Recommendations
y Accuracy
y Reoccurringfaults
y Productiongains
y Costsavings
y Financialimpact
Vibration Basics (Miller)

49

Summary:KeyPointsinaVibrationProgram
y Expertise,Technology,andWorkProcessesthat
y

PreventUnexpectedDowntime
y

ExtendMachineLifeandOptimizePerformance
y

Byassuringmachinesdonotfailcatastrophically

Bydetecting&correctingrootcauseconditionsthatcause
excessivewear

AllowYoutoWorkEfficiently
y
y

Bytrendingprogressingfaultsand
Coordinatingrepairstooccuratplannedoutages

Vibration Basics (Miller)

50