EGF oe‘CONTENTS. + s Imonance—..Page 1 Reting Comet Berge Page Sees BernghncPape Mian’ ee no Page 8 MagnmetinPoge 2 cagedetetn. Page? Amy. $2 Bes i on Ba tT Leosanen —oPope3 Balter Dac. PAge Norma GoarMaeh Page 13 Resonance Page 8 ‘ce Vans. Page Our ace ete nnn-Pane® Wom Gear..--P4G8 4 CavtonRechaton Page 18 rcblems..Page 5 Inner Re Dleton-—Pape 1 Cpe Tut. Pge 18. hcl ae Page 0 ronay paged OVERVIEW: Etch faa covered pasar fear apes wavetons ea, Wich ae aneled ik amas tps we i es ltue unas whch any he esc tae st overview coogarees no syrcverous, in-syncvenoue a ubayctonois energy ese won brow shat 508) Non-Synclraous Frequencies Sub.Syncronovs Frequncie Segeeverses, eae amy Ses 2c eae eres arte ++ Chipped | Broken Gear Teeth " — (pron ae b rou campus tom pony sponse wm SO neta EGF nyttIMBALANCE: Imbalance Detail smronges oa we te carina rs om cnet wat ong ina haa) st ‘11019 This heavy spot produces ores resuing nigh vbrton amples at's hosueney ta 10 HRPM (Tavolabotl opsea) in specral data anda sino maveleen me Sie ear On gly mounted machines ampitudes wil typically be highest in the horizontal rection versus the ‘erica rechon,athoughrased ampltadee can ah ova ously where oootions eae oa [The imbalance amltude wil increase by the square of speed (uhen the ruming speed is below the first rotor etic frequency “ = 'A30" phase diferance wi ypicaly exist between horizontal and vrical readings at eact bearing wth a pure imbalance problem. a & = EGF nyttMISALIGNMENT ‘Misalignment Detail Msatonment occurs when th shaft conranas of wo deety mating cimponents mest at angles endo te oot ‘tom one another. Misalignment of coupirgs and beatings typical este m igh vada sod anal aon ‘Angular misalignment typical produces raed axial amples with a phase ference of 180" aay across eupings, Offeet misalignment typical produces igh racial ampules ih a phese ference 180% daly ‘bss Coupings. A nisalgnmentprobiom wil pial prodce a dominant equency t tHRPM andlor 24RPM, depending upon the degree of angular misaignment versus fet micalgnmen, ae wel ax couping ype and design In soa were TaRPM dominates due toa misalgnmont problem, phase readings ae escentl fo cataguh rom ot Imtatance probiom, ‘Wovetorms pica show repeatable, por pattems wih one or wo clear cycles cer-shaft revlon, Pet EGF nyttLOOSENESS (Structural & Component en speas mcty aa ‘ne wentainceten Looseness Detail Component or Mechanical Looseness cocurs whon rotating camponents de not fi cored. A number Shaynetroncus running speed harmonics sul comnate spect data (0. 1c 10 T0xRPN. In conan Instances and stages of ceteroratan, pocral dala may also show subcmanie mUlipes of ARM or RPM, Waveforms typically show high random impacting pattems andin some instances the waveform may appear tuncatod Structural Looseness isthe result o! loose r distorted machine feet (sof foot), oose foundations ‘teak pruting, oose ols or bedpiaes. These concitons tyacalyproguce.s frequency at REM Indios RPM ada n spectral data Vora! amples may also be more predomnar depending Spon the ype of structure problem Waveform data is typically period, wih one or two cyces percha revolution, Pars EGF nyttBLADE / VANE PASS SBHECPa lass) Blade /Vane Pass Detail ALY machine which handle fds such as water, gases. air anc ol wil typically produce an inherent ‘Elan feuony (lus pool harmones) elo, Nanri oseg anes PREM Te eet ‘machine characterise normal refered to as Blago or Vane Pass Eregtoncy (aPr or VEET ‘Where a pump has difuser vanes this can also produce a frequency equal to number difisers x RPM. Excessive BPF oc VPF amplitudes can result from uneven or wom distributed gaps between rotating vanes and state diftusers Should @ BPE or VPF coincides with a system natural frequency then exxemely high destructive ‘ampites wil be experince " ” " & 18‘The at eqn ab ed a tren: i cn Bolts Detail ‘The Primary Bot Frequency (PBF) is equal othe numberof times per sec (2) or minute (CPM) that «bot rts around ts ae ystom, whieh canbe Cleat se howe J Prmary Bolt Freq = 3.142. Puley RPM x Pch Diameter o/c) Bett problems, which produce PBF andio: harmonics include; wear, cracks, mismatching, incorrect {ension, hard or sof spots tis not unusual to sae PBF harmorice m'spoctl data, and olen dx BSF (Gan.be the most dominant peak. The highest ampitudes wl tpl be radia and inne wi the Se Misaligned pulleys/belts nomally produce a 1xRPM frequency ail & a EGF nyttRecognising Bearing DefectsBEARING CAGE DEFECTS Cage Defects (FTF) Detail ‘A‘undamental train (cage) tequency (FTF) normally occurs between 0.35-0.48xRPM (eub-synchronaus energy). Cage detects are usually accompanied by other detective beating components, such as ball / roller Sialets and appear as sidand Requencies, a Cage detects often cause mid bearing failures, making them more dificult ts detec. produce high amplitudes and could potently be confused with othe ‘alt vibration fore impertant to capture highresoluion conventional Sala, a= well as ushg advanced patos. is th ing montoninglochmguos for cage defect detoclon tpplementary &BEARING BALL / ROLLER DEFECTS: Ball / Roller Defects (BSF) Detail {all Spin Frequencies (BSF) appear when damage occurs othe surface of a bearings rling elements. {all and roller defects ar ypcally non synchronous frequencies, which can appear at the fundamental [BSF or 2xBSF with associated harmony hal may 0e larger In amplitude desending upon the number ‘ol damaged roling elements, ‘tere BSF exit itis common to see the fundamental BSF or 2xB5F andlor related harmonics surounded by cage (FTF) sideband frequencies, BSF defects can also be assessed from the time waveform where impacts equal to the fundamental BSF or related predominant BSF hartonies) may be present & = 18BEARING OUTER RACE DEFECTS. Outer Race Defects (BPFO) Detail ‘Bal Pass Frequency Outer |BPFO) are created as rong elements pass across a defects) onthe outer ‘ace. The fundamental BPFO is gonoraly non-syncnronaus, atwough on some Dearings (depending ‘Upon bearing geometry) this is lose enough to appear as a Synchronous frequency. ‘This problem typically shows several harmonics ofthe fundamental BPFO, which are often higher in ampitiude, and in some instances can be surrounded by cage siceband Fequen ‘Where the outer race rotates and inner race remains statonary, BPFO frequencies can be modulated by he shat speed, resulting in running pead sidebands suraunding the BPFO detect frequencies. ‘Time waveforms typically show distinctive high impact levels ('), spaced a the fundamental BPFO or telated dominant harmonic). & EGF owerBEARING INNER RACE DEFECTS: Inner Race Defects (BPFI) Detail Ball Pass Frequency Innes (BPFI) are created as roling elemerts pass across a defect(s) on the inner ‘ce. The fundamental BPF! Is generelly non-synehronous,alfough on some bearings this Is lose ‘enough lo appear as @ synchronous Fequancy. ‘Spectral and waveform characteristics for BPFI problems are very similar to those defined for BPEO, ‘though for BPFI defects 1xRPM sidebana frequencies wil iypically suround the fundamental BPFi frequency andlor related harmonics dus modulation by the shaf speed the averse apples where te Inner race remains stationary and the cater race roles). Tess mavatorms typical show catinave nigh impact evel (93) A once per ey moda ofthe lime wavotorm typically dccurs as the BPFI faut passes trough the load zche, making he Waveform ‘appear simiar a school of angel fh & =o 18SLEEVE BEARINGS. ‘o1 Whit Instabilty Sieeve Bearing Detail ‘Sleeve bearings with excessive cleararce alow small excitation forces, such as ibs Significant vibration ampit des, rc9, to cause ‘Spectral data typically shows predominant synchronous frequencies between approximately 1x10 1GRRPM, depending on problem severty, beaing desig and arpticaton (msome eases TIM and hrmonics may ais apply) \Wped sleeve bearings can reveal higher vertical amplitudes conpared with horizontal 2 pronounced 1xRPM frequency. 1d may show ‘01 whit occurs wien the al flim in pressuredubricated systems exerts a forse that pushes the shat ‘around within the bearing, This problem typically occurs between 0.4x OxRPM, and may rel fig improper bearing design, of viscosity or pressure. Pose EGF owerGEAR ANALYSIS. + gar an equene (GF papa of ata tars HF wi vay be reer ress of ea cond, ‘SSRN USE ser on + Moser ate 3S CMF of rest jE cate ie Si ar sau conponent "oro (se soraor recone each ga oe argo) + Au oy gerbes as NOT aay a god indeaton of {Seseaces sna ant ram gn SO F Goar Mesh Calculation ‘Gear Mesn Frequency (GNF) «tao Teeth x Sat Speed Us ne oat ts ar nt speed oie othe SEE ISe ti ge t ae con GUE = rp spond Arp 40 ttn = 9867H (KEP) Fatigues / put tot =40 etn tout = 25 Coupee = atox pt spned=2 Ses = 3625p ae Sokereeoeere eee aac ‘Sensor Selection & Mounting Method Sion ose et a sense eae) ‘Sarna cewnily mons eons oesNORMAL GEAR MESH ‘Normal Gear Mesh ‘The fundamental oar meth frequency (GMF Is calculated by # Gear Teeth x Shaft RPM (apply the sat calculations every shat ne car tin, Honest fe arto GME ate oor aoa. {presenta problem, dv 1 the Inherent nature of ths frequency boing present virtual a gout Stems (Changes in fundamental GUF amplitudes may typically be the result of varying loads and speeds. Waveforms should appear atively steady wth ite sign of impacting, although ampliuses wil vary va ot Ils yea to st ne spacial requency ange oat ast 35x thefundamenta| GME (where highspeed Shaft and high GM exe, aay oe mama ressaton) ° & — Pooe 13 =WORN GEARS, Worn Gears Detail ‘Akey characteristic of wom gears isthe presence of sidebands, which show up as frequencies equal Seed ther side of te GM or relatsd harmonics. Those Sdeband frequencies wil bs equal the ‘otational speed of he shalt with the dafecive gear on. Not ony i the presence of sidebands suraunding the GMF important when analysing warn gears, but the ampitides of these sideband in relaon tothe GMP “The higher the sideband smpiitudes, the more severe the gear wear is likely tobe. ior gears can also exci the natural frequencies of he gears andior gear casing, &CHIPPED / BROKEN GEAR TEETH Chipped / Broken Gear Teeth Detail [A singe chipped or broken gear tooth wil produce @ 1xRPM vibration frequency. Its eit to ident this problem using conventional spectal dala alone, a he characters requency an eaaly be conten wt oor prodlons oeconing a REM pe “The best way of identifying this problen is by using the time comain, where a once per revolution {RPI mpoct wi be generated alowed by ang down rom fe shat the Golectve gear tooth Due to the impacting nature of hs fauithe time waveform stypcal taken nacceleration, ensuring thal the time period set-up captures as many shat revolulone a: possible, & 18MISALIGNED GEARS: Misaligned Gears Detail Misaligned gears wil generally produce ised vibration ampliudes at 2xGMF and 3xGMF, which wil ‘ypteally be Surrounded by sideband at TxRPM andlor 2xRPN, 1 essential to alvays capture at ast 3 SXGME when ether ubleshoctingortaking tn vibration ‘general ams viewing bot ne tine wavelrm and spectra data in aceseraton proves th best Fapresentaton of a gear migalgrmen: problem, parteuary where the TGR Is greater tan 1 Sk (3b ooccpmy ‘ere gear misalignment exists this i key to be accompanied by a degre of gear wear, especially ‘the probiom has been present for sometime, 1gBEAT VIBRATION: ~ s Beat Vibration Detail Beats occur when two or more primary fecuencies are very lose to one anotter causing hem to beat” toyether Beats are common where rotational speeds are runing close together, such asa belt riven motor and ump set wi a 1:1 rato, where tw ony diference between component speeds sip. The beat rauency sot the afetence between these primary equenses Beats usually cause vibration amplitudes to increase and decrease in an equally tied rythm, where ‘maximum amptudes occar when these primary Requencies Come into phase wih one anotier and ‘mnimum ampltudes occur when these primary frequencies are 180" out ol phase wilvone another \Wmen a beat is suspected itis important to capture a high-resclution ar true zoom spectrum inorder {Gcontim this problom 2 & Page? EGF nyttRESONANCE: - s Resonance Detail Fesonance i a condition wher the frequency ofan external fore coincides withthe natural (resonant) luency ofa system, resulting in drenatc (often eastous) amplludes, Using peakiphave analy {2 180" phase shit can be observed as a system approaches, erters(90" shit here) and passes tough resonance. Taking 2/3 runsupicoast dawns also allows resonant frequencies to be analysed. \¥inen resonance is suspected, look for dramatically higher amplitudes in one axis versus others. Sati impact testing allows resonant frequencies tobe identified, by impacting a system components) ‘and maasunng tha osulant requency response (use negative Inear averapng when mache cannot be stopped). Changing a systems damping, mass or stifess wil lier its ratural frequencies, alterativaly move ‘perational speeds away fom resonan: frequency regions. The unning speeds) shoud Healy be 20% figher or lower than the citical speed & Page 18 EGF nyttCAVITATION / RECIRCULATION. an Span Brann ny A “ 1 Cavitation / Recirculation Detail Gavitation occurs when the pressure of fd drops below the vapour for tke temperature of the fi, Winen a aysiem or localised pressure drop occurs, valds or caves (bubtles) wil form Whe iui ‘nese bubbles implode or calapse when the fad maves through the spelt te high pressor cess cf the pump, causing te impeller ta erode, Spectra data is cay dominated by high frequency broadband energy presen above the Impalor ‘Hade pass frequency, with random impacting present in the time waveform, os Fecrcuation occurs in tha presences ofa high suction presstre that actually pulls the Mud from the ‘put back trough the par. Recirculation is hyeraui: source of 1xRPM, as wo as sub-synchronous troadband noise. & Page 1 EGF owerELECTRICAL FAULTS. —i Sebioimes arora meres {pees (0) and sat ped (pe) Ths Sip conte xoracsad 3 re Decent Ss ner ne regan o Poo tthe oer rome yeaa Sou a ur od utr nun 1 Naboo = Seep Feeney x 120/08 Goneralised Stator Faults Detail Presence of ow amplitude electrically elated line frequencies (L) are nat uncommon in vibration data Parculary at 100Hz (2xLf] and occasional at SaFz (aL (120Hz or Ete nsome countras). However [there raised ampitides est due to an elactcal problem spectal and wavelerm can bo Used tenth the cause. BBectical problems occurrng at 2x in-use: stator eccentricity amination shorting, lose stator cores, ‘cose laminations, loose cols, loose convections and soft foul resulting ina distorted stator a gap. ere an electrical frequency could be confused witha running sped or ated harmonic frequency, {hon monitoring the wavelorm n rea-tme should see the wibratan disappear mmediasy te Supph Is switched of the problem is olociicaly related, & ——s 18ELECTRICAL FAULTS Fautty Silicon Controlled Rectifier (SCR) Cards / Supply Detail 'SCR's wil inherenty genera low ampitude vibration equal othe numberof related cardsin ating ‘yale xine frequency (1) AC fullwave recited unt with 6 Sets wil ypicaly gonscate s vbrsIeh ‘at BL, whereas ahalt-waverectied unitwin 3 SCR’ typlealy generates Sxl? Wen @ SCR unit develops a fault due to a defect cara), loose connections, shorts or open circuits this can produce many harmonics of both the Lt and SCR fring fequency: Whore ove SCR cord oF Dartsular side of the circuit matfunctons tis can also result n Wx (ul-wave rected) or" Sctrak, ‘wave reciied) and harmonics ofthe SCR fing rate Electrical Erosion is another problem exzeriencod on variable speed drives, arc is due to th passage of electcalcurents causing sparks between rolaing bearing elements Fting isa form of savanes electical erosion where the rcling surfaces give a tod” or washboard” appearance’ iting insulated bears can help eliminate eectncal erosion problems. Pa EGF owerlansford Sensors ELECTRICAL FAULTS Rotor Defects Detail standard AC nducton eto (parley where the duty re, namely caressa ad crane) ‘pos can develop problens with eccentrety 20 well ac shorted broken, cracked of loose connections ocurring inthe rote bare, end ings andor laminations. ‘Those problems can result in a predeminant 1RPM vibration surounded by sidebancs equal to the Fmbet of motor poles x sip requeny (30, Rotor ba problems can also be detocied using curent signature analysis, where sidebends equal to {he umber of poles x St, wil surround fe mais frequency (i) at SOFz or 6H. Wh tet normalised {@.60d8, these sideband amptudes vil ypicaly be 6d8 or greater when a Yolor related problem ext Fae 13a> Hansford Sensors Lo GLOSSARY: Soaenonates nies rom pare re 8 SOTERA a re eS ee ems “ee SSeS EGF ceneter