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THE MACHINE VIBRATION

ANALYSTS NEWSLETTER

FEATURED THIS ISSUE

Featured Lesson

1 Pump, Fan, and


Compressor
Vibration
Featured Article

4 Preventing faults rather


than just detecting them;
the ultimate challenge for
vibration analysts

Video

7 An Animated Introduction


to Vibration Analysis

SAVE
THE
DATE!
Series 4 | Issue 2 | August 2017

AUSTRALIA | SEPTEMBER 5 - 7, 2017


S E E B A C K C O V E R F O R D E TA I L S
About Mobius Institute
MOBIUS INSTITUTE is a worldwide provider of Reliability Improvement, Condition
Monitoring and Precision Maintenance education to industrial plant managers, reliability
engineers and condition monitoring technicians, allowing plants to be successful in
implementing Reliability Improvement programs through delivery of more easily
understandable and comprehensive training of Reliability and Vibration Analysis via
IN THIS ISSUE public, in-plant and online education programs.

Mobius Institute Board of Certification is ISO 17024 and ISO 18436-1 accredited, and
provides accredited vibration analyst certification according to ISO 18436-1 and ISO

1 FEATURED LESSON

Pump, Fan, and


18436-2.

Compressor Vibration
Key Contacts at Mobius Institute
Founder & CEO - Jason Tranter - jason@mobiusinstitute.com

4 FEATURED ARTICLE Co-founder & CFO - Georgina Breedon - georgie@mobiusinstitute.com


General Manager - Terry Blackman - terry.blackman@mobiusinstitute.com
Preventing faults rather
Certification Manager - Roberta Clark - roberta.clark@mobiusinstitute.com
than just detecting them;
North America Business Manager - Bill Slonaker - bill.slonaker@mobiusinstitute.com
the ultimate challenge for Marketing & Communications Director - Dean Lofall - dean.lofall@mobiusinstitute.com
vibration analysts IMVAC Conference Director - Becky Partipilo - becky.partipilo@mobiusinstitute.com

7 VIDEO SPOTLIGHT

An Animated Introduction


to Vibration Analysis CONTRIBUTING AUTHOR

Jason Tranter

8 SCHOLARSHIP NEWS
Founder & CEO, Mobius Institute

Q2 winners announced Jason Tranter has been involved with condition monitoring
since 1984. He is the founder and managing director of the
 Mobius Institute and the Mobius Institute Board of Certifi-
cation. Mobius Institute is ISO-accredited to ISO 17024 and
ISO 18436-1. Mobius has training centers in more than 50
countries and has trained over 22,000 people in a classroom

9
setting and many thousands more via e-learning. Jason is the
VIBRATION ANALYST HALL OF
author of the majority of Mobius classroom material and the
FAME
iLearn series of products, and is a member of ISO TC108/
Recognizing our Vibration SC5. After running a vibration consulting and software de-
Superheros velopment company in Australia in the mid-80s, Jason sold
his business and moved to the United States as the product
development manager at DLI Engineering (now Azima/DLI).
Jason has delivered presentations, workshops and had articles

10 UPCOMING COURSES
published all over the world.
See a listing of upcoming
Mobius Institute courses

SALES & SUPPORT (+1) 206-842-4000


Mobius Quick
12 TRAINING PARTNERS

Highlighting Mobius Contact


CERTIFICATION (+61) (0)3-5989-7285

Authorized Training VISIT ONLINE WWW.MOBIUSINSTITUTE.COM


Organizations
around the world EMAIL LEARN@MOBIUSINSTITUTE.COM

FEATURED LESSON FEATURED LESSON

Pump, Fan, and Compressor


Vibration

Pumps, fans and compressors can all suffer from the classic fault
conditions such as imbalance, misalignment, bearing faults, and
looseness. However, some faults are unique to these components.

There are many types of pumps in common use, and their vibration
signatures vary over a wide range. When monitoring pump vibration,
it is extremely important that the operating conditions are consistent
from one measurement to the next to assure consistent vibration
patterns. Suction pressure, discharge pressure, and especially air
induction and cavitation will affect the vibration pattern greatly.

Centrifugal pumps always have a prominent vibration component at


the vane pass frequency, which is the number of impeller vanes times
the RPM. If the amplitude increases significantly, it usually means an

VIBRATION MATTERS - AUGUST 2017 THE VIBRATION ANALYSTS NEWSLETTER 1


FEATURED LESSON FEATURED LESSON continued N

internal problem such as erosion of impellers or a flow related


problem. Harmonics of vane pass are also common in such
pumps.

Forces are generated by the pressure variations as a


rotating blade, vane, or lobe passes a stationary housing or
component.

The stationary component creates a non-uniform flow distur-


bance in the fluid or gas.

System Fluid Starvation


Other faults include the impeller loose on the shaft and pump
starvation.

When the impeller is loose on the shaft, there will be vane pass
frequency with sidebands of turning speed.

Pump starvation may look like imbalance as the flow into the
Blade Passing Frequency volute is uneven. The time waveform would show distortion due
In its broadest sense, Blade Passing Frequency includes similar to the flow being uneven. The distorted time waveform produces
components such as vanes, lobes, and pistons. The forcing harmonics of turning speed.
frequencies are:
Cavitation
Number of blades x turning speed
Cavitation normally creates random, higher frequency vibration
Number of vanes x turning speed or noise. It is often observed as a hump in the vibration
spectrum raising the floor from about 15X to 35X.
Number of lobes x turning speed
Cavitation normally indicates insufficient suction pressure or
Number of pistons x turning speed
starvation - i.e. low inlet pressure. The liquid tends to vaporize
Causes of high blade passing frequency are: while coming off the impeller creating vacuum bubbles that
implode. The waveform can often sound like gravel in the pump.

Rotor or housing eccentricity

Non-uniform variable pitch blades

Loose, bent, or misaligned housing diffuser vanes

Blade or vane wear (abrasion or cavitation)

Operation (improper performance parameters)

Improper damping settings

Dirty, damaged or missing filters


The data above is from a 20 hp centrifugal pump that has a
Inlet or discharge line restrictions

VIBRATION MATTERS - AUGUST 2017 THE VIBRATION ANALYSTS NEWSLETTER 2


FEATURED LESSON continued

cavitation problem. It sounds like it is pumping gravel. The time Harmonics


waveform is a very useful analysis tool, as the high frequency
bursts of energy are often clearly visible - however, more time Lobed blowers and screw compressors generate harmonics
data (i.e. a longer record) than normal may be needed. under normal conditions. Here is a typical example:

The spectrum reflects the impacting in the raised noise floor and
mounds of energy under the peaks. The highest peak is at vane
pass.

Sullair Rotary Screw Compressor, 1650 CFM

Turbulence Speed is 1780 CPM


Turbulence in fans, pumps, and compressors is induced when
300 HP motor
the normal flow is restricted or impeded during operation. It
shows up in spectral data as low frequency, broad peaks Female rotor has 6 vanes and the male has 4 vanes.
between 0.5 and 0.8 orders.

Causes of turbulence are:

Obstruction in air ducts or plumbing lines

Sharp radius turns in piping

Abrupt diameter changes in lines

Over capacity operation

VIBRATION MATTERS - AUGUST 2017 THE VIBRATION ANALYSTS NEWSLETTER 3


FEATURED ARTICLE

Preventing faults rather than


just detecting them; the ultimate
challenge for vibration analysts
by Jason Tranter, BE(Hons), CMRP, VA-IV
Founder & CEO of Mobius Institute
Even though a good vibration
Vibration analysts are a rare breed. From vibration readings taken on
analysis program can achieve rotating machinery they can detect all manner of fault conditions. They can
considerable savings, many do tell if the machine is misaligned, they can tell if a pump is cavitating, and
they can even tell if there is damage on the inner race of a rolling element
not achieve their full potential. bearing. All of these skills are gained through extensive training and years
of experience in the field.

A successful vibration monitoring program can greatly reduce main-


tenance costs. Downtime can be reduced, secondary damage can be
minimized, labor costs can be reduced, and safety can be improved. If
faults are detected in the earliest stages, the maintenance can be planned
to occur when it is most convenient to the plant.

Even though a good vibration analysis program can achieve consider-


able savings, many do not achieve their full potential. Vibration analysis
programs, and all other condition monitoring programs, are only there to
detect faults that exist within the machine - they do not actually improve
reliability. Sure, if you consider a reduction in catastrophic failures as an
improvement of reliability, then vibration analysis programs do improve reli-
ability. But a true measure of reliability improvement should be a reduction
in the faults that develop in the machines. Vibration analysts shouldnt
detect misalignment that results from poor alignment practices. Vibration
analysts shouldnt detect cavitation. And vibration analysts shouldnt
detect faults in rolling element bearings - unless the bearing has been
installed for a very long time.

While there are a fault conditions that will develop over a long time due
to normal wear and tear, many of the fault conditions develop because
the machine was not operated correctly, installed correctly, lubricated
correctly, aligned correctly, transported correctly, or because it was not
ideally suited to the application. Rotating machinery, and their individual
components, are all too often selected based on price and not reliability.
Lifetime costs are not taken into consideration.

Therefore, to achieve the greatest reduction in maintenance and operating


costs, the vibration analysts job should not be limited to the detection of
fault conditions. The vibration analyst should be involved with reliability
improvement. Lets explore some of the ways that the vibration analyst can
help improve reliability.

VIBRATION MATTERS - AUGUST 2017 THE VIBRATION ANALYSTS NEWSLETTER 4


FEATURED
FEATURED ARTICLELESSON
continued

Initial design and purchasing policies Field-balancing and shaft alignment


When a specification is put together for a new piece of equipment, Many vibration analysts are involved with field-balancing
achieving high reliability should be one of the key goals. The lifetime and shaft-alignment. Balancing reduces rotating forces
costs must be considered ahead of the upfront purchase price. which can damage bearings and the machine structure.
Experience with similar equipment and the suppliers should be taken Likewise shaft alignment reduces the stress on bearings,
into consideration. Maintainability should be taken into consideration. couplings, and the shaft itself. Even if the vibration analyst
does not perform the shaft alignment or balancing function,
The vibration analyst should be consulted when rotating equipment is to the analyst should take vibration readings before and after
be purchased. If the machine being considered has a history of reliabili- the work to ensure that the job is done correctly.
ty problems then it does not make sense to purchase that same type of
machine again. It is important to set targets when performing shaft
alignment and field balancing. It is not enough to simply
In an ideal world, machinery with easy-to-access monitoring points perform the job and assume that because the vibration
would be selected, but that really is hoping for too much! levels have been reduced that the job is good enough.

Standards from the ISO, API, and the US Navy are readily
Acceptance testing accessible and provide an indication of balance quality. It
There is often an assumption that components, lubricants and the is worth pointing out that while the G 6.3 standard is recom-
machines themselves are in perfect condition when they are purchased. mended in ISO 1940, G 1.0 should be the target if precision
Sadly this is not always the case. Bearings may not be transported maintenance is your goal. The equivalent API standard is
or stored correctly and may suffer from false-brinelling. Lubricants G 0.7.
may not meet cleanliness standards. Rotating machinery may suffer
from resonance and other conditions when operated under normal Rotating machinery OEMs will often provide shaft alignment
conditions. Too often rotating machinery are not designed with energy tolerances, and the laser alignment manufacturers will
efficiency and reliability in mind; instead they are designed with also provide guidelines so that a precision alignment can
purchase cost in mind. be performed every time. One standard that should not
be used is the specification provided with certain flexible
Acceptance testing provides a way to test that machines and couplings. These very loose specifications provide an
components are in good condition before they are installed in the plant. indication of what the coupling may survive but they do
Acceptance testing puts pressure on the supplier to make sure they are not provide an indication of what is best for the long-term
delivering the highest quality products. operation of the machine.

Acceptance testing guidelines can include specifications on a number Resonance correction


of parameters, but from the vibration analysts perspective the key
standard is to set vibration limits that may not be exceeded. Tests may Resonance occurs when a machine generates vibration
be performed at the OEMs workshop or after being installed on-site. It at a frequency close to a natural frequency of the rotor
is important the conditions for the test are clearly specified, including or structure. Resonance greatly amplifies the vibration
RPM, load, and mounting. amplitude; the high vibration amplitude reduces the life
of the bearings and the machine structure. The vibration
analyst can get involved in two ways.
Acceptance testing should not only be performed on new equipment, it
should be performed when repair and overhaul work is performed. This
can include motor rewinds, rotor balancing, and pump rebuilds. First the vibration analyst can identify the source of
vibration that is exciting the natural frequency and seek
to reduce that vibration amplitude. For example if there is
There are a number of ISO standards that provide guidelines for unbalance which is exciting the natural frequency then one
acceptable vibration limits when equipment is new or overhauled, and solution is to simply balance the machine.
there are a number of specifications in the public domain.

The second way that the vibration analyst can help is to


perform tests that identify the natural frequencies and then
propose modifications to the structure so that the natural

VIBRATION MATTERS - AUGUST 2017 THE VIBRATION ANALYSTS NEWSLETTER 5


FEATURED ARTICLE continued

frequencies no longer correspond to the frequencies being generated fault. Craftspeople, equipment operators, and maintenance
by the machine. The most common situation is where the running people can be sensitive to suggestions for improvements
speed of the machine corresponds with the natural frequency, however in their work. No one likes to have a finger pointed at them
other sources of vibration such as the pump vane rate, blade passing when there is an equipment failure. However, providing
frequencies and other can also excite natural frequencies. It may be short training sessions that provide information about
necessary to increase the stiffness of the structure in order to increase best practices and the benefits of improved reliability
the natural frequency so that it is no longer excited by the vibration are typically accepted with enthusiasm. When people
generated by the machine. There are a number of ways to correct recognize that improvements to reliability are encouraged
resonance; however that topic is beyond the scope of this article. and supported by management, then a persons pride and
desire for safety and plant profitability will normally kick-in
and these initiatives will be strongly supported.
Root cause analysis
Unbalance, misalignment, incorrect belt tension, poor lubrication
practices, incorrect machine operation, and resonance are common Conclusion
root causes of failures in rotating machinery, however many others An effective vibration monitoring program will always
exist. Whenever the vibration analyst detects a fault in the machine, he be required, even when the best reliability improvement
or she should always attempt to determine the root cause. Once the programs are well-established. Bearings still wear out,
root cause is identified measures should be taken so that root cause rotors become out of balance, and even the best trained
is eliminated. It is clever to be able to detect a bearing defect, but it is craftspeople make mistakes. But utilizing vibration analysis
not very clever if the same bearing exhibits the same fault condition just skills to improve reliability should always be the goal of
months later. every vibration analyst.

The vibration analyst will need to determine the most appropriate action
t
that he or she can take at their place of work to avoid a repeat of the

The Vibration Matters Brain


Teaser asks questions about
topics taught in previous
issues. Have a little fun,
answer the question and
once you do, you will see
how others have answered
too!

Q. Generally, an induction motor having an uneven/eccentric air gap will produce what
spectral characteristics?

A. Click here to select your answer on the Mobius Institute website.

VIBRATION MATTERS - AUGUST 2017 THE VIBRATION ANALYSTS NEWSLETTER 6


FEATURED VIDEO

An Animated
Vibration analysis provides
an extremely powerful

Introduction to
opportunity to learn about
the condition of rotating

Vibration Analysis
machinery but only if you
understand it and can use
it properly. Learn more in
our video.

Related Video

Utilizing Vibration Analysis to Detect


Gearbox Faults

In this Webinar we will summarize several techniques and


use animations and software simulations to make them
easier to understand.

VIBRATION MATTERS - AUGUST 2017 THE VIBRATION ANALYSTS NEWSLETTER 7


SCHOLARSHIP AWARDS

Vibration analysis is an important skill,


but being a vibration analyst, with
people counting on you to make timely,
The 2017 Q2
Scholarship Winners
accurate diagnoses, is a demanding role.
Education and accredited certification
are key to success, and the IMVAC
conferences enable analysts to further
their knowledge and meet people who We were delighted by the incredible response to the
not everyone in the world has access to
that training or the conference. While we
scholarship offer, with submissions from over 256
try to minimize costs, for a whole variety prospective vibration analysts from more than 57
of reasons those costs are too high
for some people who desire to join our different countries. Though our selection process, we
profession.
have selected the three most deserving recipients.
Mobius Institute, in association with the
IMVAC conference, would like to help
twelve people each year to achieve Eric Anti Ofori, Takoradi, Ghana
Category II certification and benefit from
the IMVAC conferences: This scholarship is indeed a dream come true for me. I have
harboured the dream of becoming a vibration analyst since the early
General Awards (twelve recipients)
days of my engineering career about 10 years ago. financial constraints
truncated my dream half way. with no hope, Mobius has resurrected
my dream with this scholarship award.
Mobius Institute Category I and
Category II Vibration Analyst Training -Eric Anti Ofori, Ghana
via Distance Learning
Mahsa Yazdanian Asr, Karaj, Iran
MIBoC Certification Examinations
for Category I and Category II certifi- In fact, this is one of the best opportunities I have ever had in my
cation according to ISO 18436 life. This is really a turning point in my professions. It can also lead
me to job promotion. Im working with all my efforts in the field of
Access to IMVAC conference pre- condition monitoring at university and industry simultaneously.
sentation and case study videos via
online access
-Mahsa Yazdanian Asr, Mapna Electric and
Top Award (one recipient) Control Engineering and Manfacturing Co (MECO), Iran

All expenses paid trip (registration, Randall C. Smith, Friendswood, Texas, USA
hotel and travel expenses) to attend
an IMVAC conference of their choice I really appreciate the scholarship offered by Mobius Institute.
As an older mechanic/millwright I am finding it more difficult to
find jobs partially because since almost all of my experience
The Q3 scholarship is now was with an oil company which made sure we knew our jobs
accepting submissions. but was not really worried about certifications. We did condition
monitoring including vibration monitoring, oil analysis, temperature
To learn more about monitoring and pressure monitoring. The companies I talk to now
the Mobius Scholarship would prefer an Associates degree or Certificate for any good
maintenance and reliability job but when was on the job training.
program visit our website. So now with this scholarship I will have something to add to my
experience while job hunting.
-Randall C. Smith, USA

VIBRATION MATTERS - AUGUST 2017 THE VIBRATION ANALYSTS NEWSLETTER 8


UPCOMING
VIBRATION
MOBIUS
HALL
COURSES
OF FAME

Roenghai Chumai
CAT IV
Certificate: M-6966-01
Exp: 27 June 2019
Location: Rayong, TH

Joo PedroPais
CAT IV
Certificate: M-6970-01
Exp: 27 June 2019
Location: Banchory, UK

ISO Category IV Vibration


Analysts are an elite group HosseinVarvani Farahani
CAT IV
of specialists that carry the Certificate: M-6975-01
highest regard in the field Exp: 30 June 2019
Location: Arak, Markazi, IR
of Condition Monitoring,
at Mobius Institute we AmirKaram
recognize them VIBRATION CAT IV
SUPERHEROS. Certificate: M-6965-01
Exp: 5 August 2019
Location: Cairo, EG

VIBRATION SUPERHEROS are qualified


to lead condition monitoring teams and LucaAmoroso
have a deep understanding of machine CAT IV
dynamics and failure modes. Their Certificate: M-6972-01
knowledge and qualifications allow them Exp: 9 September 2019
to design tests to solve difficult problems Location: Desio, IT
and identify underlying issues to prevent
reoccurrence. There are no rotating
machines problems too difficult to solve. SaschaHein
CAT IV
Mobius Institute would like congratulate Certificate: M-8301-01
all of our Vibration Superheros and take Exp: 10 October 2019
the opportunity recognize several of you Location: Ismaning, DE
in each issue of Vibration Matters.

You can become a VIBRATION GaryBehrens


SUPERHERO TOO! Mobius Institute is CAT IV
holding three more CAT-IV courses (and Certificate: M-6963-01
exams) in 2017. To learn more about Exp: 10 December 2019
CAT-IV blended training click here. To Location: Cambelltown, NSW, AU
see our 2017 schedule of courses, click
here.

VIBRATION MATTERS - AUGUST 2017 THE VIBRATION ANALYSTS NEWSLETTER 9


UPCOMING MOBIUS COURSES

We offer public and on-site training courses in


CAT - I CAT - II CAT - III CAT - IV OTHER
50 countries worldwide. See our website for a
complete course list.

ISO 18436 CAT-I VIBRATION ANALYST Course[+] ISO 18436 CAT-III VIBRATION ANALYST Course[+]

7/26/2017 Lahore, PK 4 Days 8/21/2017 Perth, AU 5 Days


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ISO 18436 CAT-IV VIBRATION ANALYST Course - Part 2[+] ISO 18436 CAT-I VIBRATION ANALYST Course[+]

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ISO 18436 CAT-II VIBRATION ANALYST Course[+] ISO 18436 CAT-II VIBRATION ANALYST Course[+]

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7/31/2017 Johannesburg, ZA 5 Days 8/22/2017 Dallas, Tx, US 4 Days


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8/14/2017 Kuala Lumpur, MY 4.5 Days 9/11/2017 Edmonton, Ab, CA 5 Days


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VIBRATION MATTERS - AUGUST 2017 THE VIBRATION ANALYSTS NEWSLETTER 10


CAT - I CAT - II CAT - III CAT - IV OTHER

ISO 18436 CAT-I VIBRATION ANALYST Course[+] ISO 18436 CAT-I VIBRATION ANALYST Course[+]

9/11/2017 Oslo, NO 4 Days 9/18/2017 Vienna, AT 4 Days


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11 VIBRATION MATTERS - JUNE 2017 THE VIBRATION ANALYSTS NEWSLETTER 11


OUR TRAINING PARTNERS OUR TRAINING PARTNERS

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(+1) 877 550 3400

VIBRATION MATTERS - AUGUST 2017 THE VIBRATION ANALYSTS NEWSLETTER 12

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