Presented By:

Michael Miller
RE Mason
Operational Challenges of Today
‘Our target is zero unplanned downtime’
y Maximize Equipment Availability & Reliability
y Plan ALL Maintenance ‐ HOW?

‘We are trying to be competitive today with a plant 
that is  typically more than 40 years old ‐ and so 
are our competitors.’
y Extend Machinery Life & Rebuilds

‘We are running our equipment beyond its design
capacity to handle the variety of materials that we 
must process’
y Increased throughput without RISK of machine failure?
Vibration Basics (Miller) 2
Answer These Tough Questions...
What maintenance does the machine need during the 
next planned shutdown?
y Do I have the parts, do I have the people ?
Can the equipment run beyond the next scheduled 
outage? 
y What work can I safely schedule out until the next 
shutdown?

Vibration Basics (Miller) 3

What is Vibration ?
y Vibration – The 
motion of a body 
about a reference point 
y At its simplest, 
vibration is displayed 
as displacement over 
time

Vibration Basics (Miller) 4

Why Use Vibration Analysis?
"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) 5

Overall Versus Spectrum

y Overall can let you know that there is a problem
y “Hey Fred, something is wrong with your car!”

y Spectrums can tell you what the problem is
y “Hey Fred, your water pump is bad!”

Vibration Basics (Miller) 6

The Units
Displacement accentuates 
the low frequencies ‐ Mils
Acceleration accentuates 
the higher frequencies 
(g’s)
Velocity is consistent across 
a larger range of  
frequencies 

Most vibration is 
analyzed in Velocity since 
the energy level is 
consistent throughout the 
frequency range.
Vibration Basics (Miller) 7
How do we measure vibration?
y Three types of sensors
y Displacement, Velocity,  Acceleration
y Signal processor of some type (CSI 2130)
y Local or portable display for field analysis
y Remote 
y Software for viewing and storing collected vibration 
data

Vibration Basics (Miller) 8

Displacement Probes
Typical Applications
y Sleeve bearings 
y Most turbine and large motor
driven machinery
y Main turbine generators
y Boiler feed water pumps
y Applications in which ‘X‐Y’ data is required for 
measurements such as
y Shaft centerline from DC gap data
y Orbits from vibration data
y Not practical for bearing or gear analysis

Vibration Basics (Miller) 9

Electromagnetic Induction

Vibration Basics (Miller) 10

Velocity Pickup
y Velocity Sensor Application
y Mounted on case of machine or shaft 
riders
y Used on sleeve and roller bearings 
depending on the application
y When integration to displacement is 
required
y Hi‐temperature
y Up to 900°F or higher
Vibration Basics (Miller) 11
Theory of Operation – Velocity 
Pickups Bobbin
Spring
Bobbin
y Mechanical
N Pole
y Moving coil
y Self‐powered

y Directional  S
Magnet

Vibration Basics (Miller) 12

Accelerometer
y Accelerometer Applications
y Case mounted or magnet mounted
y Primarily Roller‐element Bearings and Gears
y When analysis and diagnostics are important

Vibration Basics (Miller) 13

Accelerometer
Amplifier
Preload
Insulator Bolt

Conductive Inertial
Plate Mass
Piezoelectric
Insulator Crystal

Vibration Basics (Miller) 14

Amplitude

Tim
e
Amplitude

Amplitude
y
e nc
u
req
Tim F
e

Vibration Basics (Miller) 15

Signal Processing – The Mystery
1.5

0.5
Amplitude

0 Turning Speed

-0.5

-1

Time
-1.5

Turning Speed Time Waveform

Vibration Basics (Miller) 16
Signal Processing
1.5

0.5
Amplitude

Turning Speed
0
2x TS

-0.5

-1

-1.5

Time
Add twice turning speed vibration
Vibration Basics (Miller) 17
Signal Processing
1.5

1
Amplitude

0.5

Turning Speed
0 2x TS
7x TS

-0.5

-1

-1.5
Time
Add blade pass vibration
Vibration Basics (Miller) 18
Signal Processing
1.5

0.5
Amplitude

Turning Speed
2x TS
0
7x TS
Brg

-0.5

-1

-1.5
Time

Add Bearing Vibration

Vibration Basics (Miller) 19
Signal Processing
Total Vibration
3

-1

-2

-3

Vibration Basics (Miller) 20

 Signal Processing – break down complex waveform in to 
waveform components
The Fast Fourier Transform (FFT) takes the complex waveform and
breaks it down into the component sine waves
3 1.5

2 1

1 0.5

0
FFT 0

-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

Signal Processing – The FFT or Spectrum
Spectrum (FFT)
1.4
Twice
Turning
Speed
1.2

Turning
Speed
1
Amplitude

0.8

0.6
Blade
Pass
0.4

Bearing
Frequency
0.2

0
1
12
23
34
45
56
67
78
89
100
111
122
133
144
155
166
177
188
199
210
221
232
243
254
265
276
287
298
309
320
331
342
353
364
375
386
397
Frequency
Vibration Basics (Miller) 22
So What can Vibration Analysis Detect?

y Detect and Track progressing stages of Bearing Failure
y Identify Imbalance and Misalignment
y Vibration Analysis is used to correct Imbalance

y Identify/correct Resonance
y Identify Mechanical Wear in couplings, bearings, support 
structures, etc.
y Detect other defects such as:  
y Lube failure / soft foot / broken rotor bars
y Pump cavitation, and many more…

Vibration Basics (Miller) 23

What is a Vibration Program?
y Expertise, Technology, and Work Processes that
y Prevent Unexpected Downtime
y By assuring machines do not fail catastrophically

y Extend Machine Life and Optimize Performance
y By detecting & correcting root cause conditions that cause 
excessive wear Do the right work…
At the right time…
y Allow You To Work Efficiently
With the right methods…
y By trending progressing faults and…
y Coordinating repairs to occur at planned outages

Vibration Basics (Miller) 24

A Few Case Histories to Get You Thinking

y Paper Mill: 
y On‐line vibration monitoring detected a cracked shaft 
y Press section
y Trend increased drastically over 36 hour period
y Would have otherwise failed catastrophically

y Offshore Oil Platform:
y On‐line vibration monitoring saves compressor twice!
y Bearing problem detected through vibration analysis.  
y Bearing was replaced. 
y New fault detected 6 hours later
y Thermal expansion created bearing misalignment

Vibration Basics (Miller) 25

A Few Case Histories to Get You Thinking
• Cement Mill:
– On‐line vibration monitoring solves mystery 
– Air handler with intermittent high vibration
• Resonance occurs when baffle open at ~61%.  

• Power Plant:
– On‐line vibration extends maintenance intervals
• Preventive turbine maintenance every 5 years
– Unnecessary maintenance can induce faults!  
• Extend from 6 – 10 years with on‐line monitoring
– Average repair cost around $1 million 

Vibration Basics (Miller) 26

Where Should Vibration Analysis be Used?
Plant Equipment

y Predictive
y Critical to production
y Preventive
y Support equipment
y Reactive
y Easy/Inexpensive to replace

Vibration Basics (Miller) 27

Establishing a Vibration Program

y Define program focus / resources
y Determine collection method(s)
y Create database
y Collect data
y Detect developing faults
y Diagnose nature and extent of fault
y Document business and maintenance implications

Vibration Basics (Miller)

28
1) Define Program Focus
y Identify Critical Machines
y Effect on production
y Availability of back‐up machine
y Cost to repair
y Time to repair

y Determine Resources
y Fully in‐house staffed
y Fully out‐sourced 
y Combination:  Startup, Initial contract service, etc.

Vibration Basics (Miller) 29

2) Determine Collection Method(s)
y Route‐based periodic  y Online monitoring
y General plant  y Critical equipment
equipment y Installed sensors
y Walk around survey y Automatic monitoring
y Manual measurement y Define measurement 
y Monthly reading typical interval
y Readily accessible y Inaccessible or 
hazardous areas

Vibration Basics (Miller) 30

3) Create Database
y Enter machine configuration information
y Machine ID (asset code) and Description
y Machine Design info, Operating Speed, etc.

y Define measurement points
y Point ID (identification) and Description
y Sensor Type (accelerometer)
y Analysis Parameters (how to analyze signal)
y Alarm Limits (allowable amount of vibration)

Vibration Basics (Miller) 31

Data Collection Points ‐ Nomenclature
MOH MIH PIH POH
MOP MIP PIP POP
MOV MIV PIV 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

Collect Data (Survey)

1) Periodic survey with 
walk‐around Portable 
Analyzer

2) Continuous survey with 
online monitoring 

Vibration Basics (Miller) 33

 5) Detect Developing Faults
Visual detection using
color and shape

Vibration
divided
into
Entire machine train frequency
on one screen bands

Motor Gearbox Pump

Vibration Basics (Miller) 34
6)  Diagnose Nature of Fault
y Each machine fault generates a specific vibration 
pattern (Bearings, Belts, etc.) 

y A single vibration measurement provides 
information about multiple components

y The frequency of the vibration is determined by 
the machine design and operating speed

Vibration Basics (Miller) 35

6)  Diagnose Nature of Fault
Knowing the accurate 
machine speed and 
phase is important for 
vibration analysis.

A tachometer is required to determine machine speed 
and phase. 

Vibration Basics (Miller) 36

6)  Diagnose Nature of Fault
Trend shows rate of
advancement
for fault in question Individual trend
parameter covers
suspect frequency
range

Vibration Basics (Miller) 37

 Sub-
Harmonic 1X 2X Bearing Bearing Gears Bearing
Amplitude

1x 2x 50x
Trend of
Trend of Bearings
Balance
5
mm/sec Alarm
1
Time mm/sec Time
(Days) (Days)

Alert and Fault alarms for each parameter

Vibration Basics (Miller) 38

6) Diagnose Nature of Fault

Imbalance typically appears at the

turning speed of the machine

Imbalance

Vibration Basics (Miller) 39

6) Diagnose Nature of Fault

Misalignment typically shows up at

either 1 or 2 x turning speed

Misalignment

Vibration Basics (Miller) 40

6) Diagnose Nature of Fault

Looseness shows up as
multiples of turning speed

Looseness

Vibration Basics (Miller) 41

6) Diagnose Nature of Fault

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

Roller Bearing Faults
Four different bearing frequencies

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 can’t
be detected with standard vibration
measurements.

Vibration Basics (Miller) 46

Sidebands Many distinct peaks
increase with
gear wear

Gear Wear

Vibration Basics (Miller) 47

Examples of Orbits
Misalignment, Misalignment
Resonance, Wear
Ellipse Truncation

Misalignment Shaft rub or

mechanical looseness
“Banana” Inside ellipse

Misalignment Sub-synchronous whirl

and other problems
“Figure Eight” Inner loop

Vibration Basics (Miller) 48

7) Document Business 
& Maintenance Implications
y Document:
y Diagnoses
y Recommendations
y Accuracy
y Reoccurring faults
y Production gains
y Cost savings
y Financial impact

Vibration Basics (Miller) 49

Summary:  Key Points in a Vibration Program

y Expertise, Technology, and Work Processes that
y Prevent Unexpected Downtime
y By assuring machines do not fail catastrophically

y Extend Machine Life and Optimize Performance
y By detecting & correcting root cause conditions that cause 
excessive wear

y Allow You to Work Efficiently
y By trending progressing faults and…
y Coordinating repairs to occur at planned outages

Vibration Basics (Miller) 50