Establishing Vibration

Measurement Sites,
Parameters, and Alarms

2006-12-07 ©SKF Slide 2 [Code]

SKF [Organisation]
 Module objective

To introduce the concepts of:

• Setting up vibration measurement sites and parameters.
• Different types of condition monitoring alarms
• Vibration signal processing methods

2006-12-07 ©SKF Slide 3 [Code]

SKF [Organisation]
Condition-based monitoring systems

Local Protection Systems

• Simultaneous data collection
• Protect critical equipment
• Provide automatic shutdown features
Surveillance Systems
• Periodically monitor equipment
• Useful in harsh environments
• Provide predictive maintenance features
Portable Systems for periodic data collection
• Balance of plant

2006-12-07 ©SKF Slide 4 [Code]

SKF [Organisation]
Overall vibration

q.
h fre
h ig

y
tim enc
e q u
fre
q. fre
low

individual vibration signals

combine to form a complex
time waveform
complex time waveform

2006-12-07 ©SKF Slide 5 [Code]

SKF [Organisation]
 Setting up the measurement

Physical considerations
• Selecting measurement sensor orientations
• Selecting sensor locations
• Surface preparation
• Sensor mounting techniques
Database considerations
• Measurement types (multi-parameters)
• Measurement settings (including scale factors)
• Alarm limits

2006-12-07 ©SKF Slide 6 [Code]

SKF [Organisation]
Consistency!

Consistency between measurements is essential!

• Collected vibration data must be comprehensive and
repeatable
• Measurements should be taken at the same exact
location for comparison to previous readings
• Perform measurements with the machine operating
under similar operating conditions / speed / temperature

2006-12-07 ©SKF Slide 7 [Code]

SKF [Organisation]
 Asset Information Pages

• Walk through
• Asset Information Pages

2006-12-07 ©SKF Slide 8 [Code]

SKF [Organisation]
Measurement sensor orientations…

• Radial (2 Data)
• Horizontal

• Vertical

• Axial (1 Data)

2006-12-07 ©SKF Slide 9 [Code]

SKF [Organisation]
Measurement sensor orientations

On horizontal machinery:
• Horizontal - Measurements typically show higher amplitudes since
most machines are more flexible in the horizontal plane.
• Vertical - Measurements typically show lower vibration amplitudes
than horizontal due to the increased vertical stiffness and gravity.
• Axial - Under ideal conditions, axial readings should have low
vibration readings, as most forces are generated perpendicular to the
shaft. However, problems such as misalignment or a bent shaft
create vibration in the axial plane as well as some bearing faults.
The most important determinate of transducer placement are the
proximity to the bearing and a stable mounting point.

2006-12-07 ©SKF Slide 10 [Code]

SKF [Organisation]
 Sensor location - qualifying and identifying…

Measurement point numbering

follows flow of power:

• Motor Non-Driven End (NDE)

• Motor Driven End (DE)
• Pump Driven End (DE)
• Pump Non-Driven End (NDE)

2006-12-07 ©SKF Slide 11 [Code]

SKF [Organisation]
 Sensor location - qualifying and identifying…

4-bearing, horizontally mounted

pump:

• MOTOR NON-DRIVEN END (NDE or

OB) = 1H, 1V, 1A

• MOTOR DRIVEN END (DE or IB) =

2H, 2V

• PUMP DRIVEN END (DE or IB) = 3H,

3V

• PUMP NON-DRIVEN END (NDE or

OB) = 4H, 4V, 4A

2006-12-07 ©SKF Slide 12 [Code]

SKF [Organisation]
Sensor location - qualifying and identifying…

• Vertical pumps have a radial reading

(R) taken down the plane of the
system, 90o perpendicular to the
plane of the discharge volute.

2006-12-07 ©SKF Slide 13 [Code]

SKF [Organisation]
Sensor location - qualifying and identifying…

• Vertical pumps have a radial reading

(R) taken down the plane of the
system, 90o perpendicular to the
plane of the discharge volute.

2006-12-07 ©SKF Slide 14 [Code]

SKF [Organisation]
Sensor location - qualifying and identifying…

Geared
driver/driven
system

2006-12-07 ©SKF Slide 15 [Code]

SKF [Organisation]
 Sensor location - qualifying and identifying

• Motors having lightweight, or

“ringer” bellhousings may require an
access hole cut into the bellhousing

• If no suitable access is available, do

not take data on the bellhousing

• The numbering convention is kept

intact (NDE to DE, etc.)

2006-12-07 ©SKF Slide 16 [Code]

SKF [Organisation]
Sensor location - qualifying and identifying

• Motors having lightweight, or

“ringer” bellhousings may require an
access hole cut into the bellhousing

• If no suitable access is available, do

not take data on the bellhousing

• The numbering convention is kept

intact (NDE to DE, etc.)

2006-12-07 ©SKF Slide 17 [Code]

SKF [Organisation]
 Measurement settings

Key parameters:
• Measurement units
• Data collector and transducer /
sensor specifics
• The type of data – overall,
spectrum, envelope, etc.
• Frequency range and spectrum
setup Information (lines,
window, etc.)

2006-12-07 ©SKF Slide 18 [Code]

SKF [Organisation]
Enveloped acceleration measurement

• Acceleration is most useful in higher frequency events, such as

bearing and gearbox vibration
• Since low frequency energy can dynamically dominate the
measurement to the point where bearing defects are not detectable
even in moderately advanced stages of wear, a special measurement
specifically designed for detection of bearing defects, enveloped
acceleration, or gEx (where x is the applicable filter, based on running
speed) may be used

2006-12-07 ©SKF Slide 19 [Code]

SKF [Organisation]
Concepts/Implementing Slide 47

Data collection guidelines

Bearing Band
Single Band Set Band Frequency
Banding Setpoints Range of band from
(for Peak Alert Screening) fmin = 5xRPM to fmax
Full Save Avg Lines Peak fmin fmax Peak Peak
Pt. fmax fmin Scale Data Resol Pk-Pk A1 A2 Alert Danger
CPM CPM
CPM CPM Peak Overall
Type Alert Danger Alert Danger
Rolls/ ips 1 FFT 2 Pk 0.15 0.30 0.15 0.30
Cylinders gE2 12k 0.4N 5 FFT&Time 1 800 Pk-Pk 0.5 1 0.4N 12k 0.15 0.3 1 2
PAPER <300rpm gE3 5 FFT&Time 1 Pk-Pk 1 2
MACHINE
ROLLS Rolls/ ips 1 FFT 2 Pk 0.15 0.30 .15 0.30
Cylinders gE2 24k 0.4N 5 FFT&Time 1 800 Pk-Pk 0.5 1 0.4N 24k 0.15 0.3 1 2
>300rpm gE3 5 FFT&Time 1 Pk-Pk 1 2

< = 1200rpm ips 12k 1 FFT 4 Pk .314 .628 12k .314 .628
SIMPLE gE3 60k 25 FFT&Time 2 Pk-Pk 4 10 60k 4 10
MOTORS ips 12k 0.4N 1 FFT 4 800 Pk .314 .628 0.4N 12k .314 .628
1200-2400rpm
FANS FFT&Time
PUMPS gE3 60k 25 2 Pk-Pk 4 10 60k 4 10
>2400rpm ips 30k 1 FFT 4 Pk .314 .628 30k .314 .628
COMPRESSORS
gE3 120k 25 FFT&Time 2 Pk-Pk 4 10 120k 4 10

ips 30k 1 FFT 4 Pk .314 .628 30k .314 .628

4(NT)
+10 FFT
GEARBOXES g %
0.4N 5 4 800 Pk 2 3.5 0.4N 120k 2 3.5
See
Note
gE3 120k 25 FFT&Time 2 Pk-Pk 4 10 120k 4 10
• N = Machine/component running speed.
• Calculate gearbox fmax CPM = [4(NT)+10%] = [4* (shaft speed)*(No. of gear teeth on shaft)+10%]
• Assumes Accelerometer. If machine running speed is <120rpm, use low-frequency accelerometer.
• fmin setpoints are based on 0.4N of lowest RPM component in train.

2006-12-07 ©SKF Slide 20 [Code]

SKF [Organisation]
General parameter recommendations

General recommendations for basic machines:

• Low frequency cutoff - 1/10 of the running speed
• First four lines of resolution (bins) should be ignored when
integrating acceleration to velocity, and the first eight lines when
double-integrating to displacement
• Maximum frequency (Fmax) for rolling element bearings should be
40 to 50 times running speed
• Fmax for plain or sleeve-type bearings should be 10 to 20 times
running speed
• Use 800 lines of resolution for all spectra
• Use 6 to 8 averages unless measurement is particularly noisy.

2006-12-07 ©SKF Slide 21 [Code]

SKF [Organisation]
Measurement interval guidelines

• Monitoring frequency based on how critical the machine is to

production, safety, and other production/economic factors.

• Once an alarm is reached, measurement intervals should be

increased and other parameters such as temperature should be
considered.

2006-12-07 ©SKF Slide 22 [Code]

SKF [Organisation]
Quick review

QUESTIONS ?

2006-12-07 ©SKF Slide 23 [Code]

SKF [Organisation]
Condition Monitoring Alarms

2006-12-07 ©SKF Slide 24 [Code]

SKF [Organisation]
 Types of alarms

• Alarm methods and settings must be consistent to detect key

events, yet be forgiving enough to permit normal operating
transients.
• As the program matures, more systemic screening techniques
develop, allowing more selective data screening and alarm settings.
• Overall vibration limits
• Spectrum enveloping
• Spectrum bands
• Percentage change, statistical,
and forecast alarms

• Phase alarms

2006-12-07 ©SKF Slide 25 [Code]

SKF [Organisation]
Overall vibration evaluation options

• ISO Standard Comparison

Compare values to the limits established in the ISO Standard.

• Trend Comparisons
Compare current values with values obtained over a period of time. Vibration analysis
software provides trending features for automatic trend plotting.

• Baseline Comparison
• Comparison with Similar Machinery
Measure several machines of a similar type under the same conditions and judge the
results by mutual comparison.

If possible, use all four comparisons to evaluate your machinery's condition.

Trend comparisons should always be used.

2006-12-07 ©SKF Slide 26 [Code]

SKF [Organisation]
ISO overall vibration severity guidelines

acceleration - Gs (peak)

velocity - in/sec (peak)

Frequency - CPM

2006-12-07 ©SKF Slide 27 [Code]

SKF [Organisation]
 ISO guidelines…

ISO 10816-1
overall velocity
vibration guidelines

2006-12-07 ©SKF Slide 28 [Code]

SKF [Organisation]
Overall vibration

• The mainstay of inexpensive hand-held vibration monitoring tools

• Total vibration energy measured within a specific frequency range
• When comparing overall values, it is important that both overall
values be obtained from the same frequency range
• It is most desirable to specify an alert threshold high enough to
minimize extraneous alarms, yet conservative enough to not miss a
critical excursion in machine condition.

2006-12-07 ©SKF Slide 29 [Code]

SKF [Organisation]
 Overall vibration trend plot

Alert and Danger “Level” Alarms

2006-12-07 ©SKF Slide 30 [Code]

SKF [Organisation]
 Spectrum enveloping alarms

2006-12-07 ©SKF Slide 31 [Code]

SKF [Organisation]
 Spectrum band alarms

2006-12-07 ©SKF Slide 32 [Code]

SKF [Organisation]
Enveloping alarm guidelines

2006-12-07 ©SKF Slide 33 [Code]

SKF [Organisation]
 SEE technology - Spectral Emitted Energy

SEE
sensor

• Lubrication problems
• Early (incipient) detection of bearing and gearmesh faults

2006-12-07 ©SKF Slide 34 [Code]

SKF [Organisation]
SEE numerical analysis

0-3 no identifiable problems

3 - 20 lubrication problem,
contamination, bearing
defect with light load, or a
small

bearing defect with normal

load
20-100 bearing defect or
contamination
100+ severe bearing problem

2006-12-07 ©SKF Slide 35 [Code]

SKF [Organisation]
 SEE spectrum analysis

2006-12-07 ©SKF Slide 36 [Code]

SKF [Organisation]
HFD - high frequency detection

• Effectively monitors high frequency range

• Uses sensor resonance to amplify low energy bearing fault signals
• Produces a numerical value for “good/bad” detection

2006-12-07 ©SKF Slide 37 [Code]

SKF [Organisation]
Quick review

QUESTIONS ?

2006-12-07 ©SKF Slide 38 [Code]

SKF [Organisation]