Chapter 2

VIBRATION ANALYSIS APPLICATIONS

The use of vibration analysis is not restricted to predictive maintenance. This tech-
nique is useful for diagnostic applications as well. Vibration monitoring and analysis
are the primary diagnostic tools for most mechanical systems that are used to manu-
facture products. When used properly, vibration data provide the means to maintain
optimum operating conditions and efficiency of critical plant systems. Vibration anal-
ysis can be used to evaluate fluid flow through pipes or vessels, to detect leaks, and to
perform a variety of nondestructive testing functions that improve the reliability and
performance of critical plant systems.

Some of the applications that are discussed briefly in this chapter are predictive main-
tenance, acceptance testing, quality control, loose part detection, noise control, leak
detection, aircraft engine analyzers, and machine design and engineering. Table 2.1
lists rotating, or centrifugal, and nonrotating equipment, machine-trains, and continu-
ous processes typically monitored by vibration analysis.

Table 2.1 Equipment and Processes Typical0 Monitored by Viiration Analysis

Centrifugal Reciprocating Continuous Process
Pumps Pumps Continuous casters
Compressors Compressors Hot and cold strip lines
Blowers Diesel engines Annealing lines
Fans Gasoline engines Plating lines
Motorigenerators Cylinders Paper machines
Ball mills Other machines Can manufacturing lines
Chillers Pickle lines
continued

3
4 Vibration Fundamentals

Table 2.1 Equipment and Processes Typically Monitored by VZrationAnalysis

Centrifugal Machine-Tkains Continuous Process

Product rolls Boring machines Printing
Mixers Hobbing machines Dyeing and finishing
Gearboxes Machining centers Roofing manufacturing lines
Centrifuges Temper mills Chemical production lines
Transmissions Metal-working machines Petroleum production lines
Turbines Rolling mills, and most Neoprene production lines
Generators machining equipment Polyester production lines
Rotary dryers Nylon production lines
Electric motors Flooring production lines
All rotating machinery Continuous process lines

Source: Integrated Systems, Inc.

MAINTENANCE
PREDICTIVE
The fact that vibration profiles can be obtained for all machinery that has rotating or
moving elements allows vibration-based analysis techniques to be used for predic-
tive maintenance. Vibration analysis is one of several predictive maintenance tech-
niques used to monitor and analyze critical machines, equipment, and systems in a
typical plant. However, as indicated before, the use of vibration analysis to monitor
rotating machinery to detect budding problems and to head off catastrophic failure is
the dominant predictive maintenance technique used with maintenance management
programs.

ACCEPTANCETESTING
Vibration analysis is a proven means of verifying the actual performance versus
design parameters of new mechanical, process, and manufacturing equipment. Preac-
ceptance tests performed at the factory and immediately following installation can be
used to ensure that new equipment performs at optimum efficiency and expected life-
cycle cost. Design problems as well as possible damage during shipment or installa-
tion can be corrected before long-term damage and/or unexpected costs occur.

QUALITY CONTROL
Production-line vibration checks are an effective method of ensuring product qual-
ity where machine tools are involved. Such checks can provide advanced warning
that the surface finish on parts is nearing the rejection level. On continuous pro-
cess lines such as paper machines, steel-finishing lines, or rolling mills, vibration
 Vibration Analysis Applications 5

analysis can prevent abnormal oscillation of components that result in loss of

product quality.

LOOSEOR FOREIGNPARTS DETECTION

Vibration analysis is useful as a diagnostic tool for locating loose or foreign objects in
process lines or vessels. This technique has been used with great success by the
nuclear power industry and it offers the same benefits to non-nuclear industries.

NOISECONTROL
Federal, state, and local regulations require serious attention be paid to noise levels
within the plant. Vibration analysis can be used to isolate the source of noise gener-
ated by plant equipment as well as background noises such as those generated by
fluorescent lights and other less obvious sources. The ability to isolate the source of
abnormal noises permits cost-effective corrective action.

LEAKDETECTION
Leaks in process vessels and devices such as valves are a serious problem in many
industries. A variation of vibration monitoring and analysis can be used to detect leak-
age and isolate its source. Leak-detection systems use an accelerometer attached to
the exterior of a process pipe. This allows the vibration profile to be monitored in
order to detect the unique frequencies generated by flow or leakage.

AIRCRAFTENGINEANALYZERS
Adaptations of vibration analysis techniques have been used for a variety of specialty
instruments, in particular, portable and continuous aircraft engine analyzers. Vibration
monitoring and analysis techniques are the basis of these analyzers, which are used
for detecting excessive vibration in turboprop and jet engines. These instruments
incorporate logic modules that use existing vibration data to evaluate the condition of
the engine. Portable units have diagnostic capabilities that allow a mechanic to deter-
mine the source of the problem while continuous sensors alert the pilot to any devia-
tion from optimum operating condition.

MACHINE
DESIGNAND ENGINEERING
Vibration data have become a critical part of the design and engineering of new
machines and process systems. Data derived from similar or existing machinery can
be extrapolated to form the basis of a preliminary design. Prototype testing of new
machinery and systems allows these preliminary designs to be finalized, and the
vibration data from the testing adds to the design database.