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INDICE

INDICE 1

CHAPTER 1 4
1.1 INTRODUCTION ............................................................................................. 4
1.2 CONDITIONS FOR SUCCESS .................................................................................. 4
1.3 DEFINITION OF GOALS AND OBJECTIVES .................................................................... 5
1.4. MANAGEMENT'S SUPPORT .................................................................................. 6
1.5. PERSONNEL IN CHARGE OF THE PREVENTIVE-PREDICTIVE MAINTENANCE SYSTEM ........................... 6
1.6. IDEAL CHARACTERISTICS OF A VIBRATION ANALYST ........................................................ 7
1.7 IDEAL CHARACTERISTICS OF A PERSON IN CHARGE OF MAINTENANCE ......................................... 8
CHAPTER 2 11
2.1 INTRODUCTION ........................................................................................... 11
2.2 FORMATION OF THE PREDICTIVE MAINTENANCE GROUP .................................................... 11
2.3 PLANT'S MAINTENANCE DIRECTOR ......................................................................... 11
2.4 VIBRATION ANALYST ...................................................................................... 12
2.5 THE PERSON IN CHARGE OF MAINTENANCE ................................................................ 13
2.6 TECHNICAL DEPARTMENT ................................................................................. 14
2.7 CONCLUSIONS ............................................................................................ 15
CHAPTER 3 17
3.1 INTRODUCTION ........................................................................................... 17
3.2 MINIMUM TRAINING REQUIREMENTS ....................................................................... 17
3.3 BASIC LEVEL IN VIBRATION ANALYSIS ..................................................................... 17
3.4 INTERMEDIATE LEVEL IN VIBRATION ANALYSIS ............................................................. 18
3.5 ADVANCED LEVEL IN VIBRATION ANALYSIS ................................................................. 19
3.6 TRAINING IN THE USE OF INSTRUMENTS AND THE PREDICTIVE MAINTENANCE SYSTEM ...................... 19
3.7 VIBRATION ANALYSIS QUESTIONNAIRE ..................................................................... 20
3.8 ADDITIONAL TRAINING .................................................................................... 20
CHAPTER 4 28
4.1 INTRODUCTION ........................................................................................... 28
4.2 SELECTION PROCEDURE ................................................................................... 28
4.3 PRIORITY 1, VERY CRITICAL EQUIPMENT .................................................................. 28
4.4 PRIORITY 2, CRITICAL EQUIPMENT ........................................................................ 29
4.5 PRIORITY 3, EQUIPMENT WITH NORMAL PRIORITY ......................................................... 29
4.6 PRIORITY 4, EQUIPMENT WITH LOW PRIORITY............................................................. 30
4.7 CONCLUSIONS ............................................................................................ 30
CHAPTER 5 35
5.1 INTRODUCTION ........................................................................................... 35
5.2 COMMENTS ABOUT THE FORMATS ......................................................................... 35
CHAPTER 6 55

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6.1 INTRODUCTION ........................................................................................... 55

6.2 DIFFERENT TYPES OF SPECTRAL BAND ALARMS ............................................................ 56
6.3 VIBRATION-MOVEMENT, SPEED AND ACCELERATION PARAMETERS .......................................... 56
6.4 PROBLEMS THAT CAN BE DETECTED WITH VIBRATION ANALYSIS ............................................ 58
6.5 VIBRATION GLOBAL VALUE (GV) SPECIFICATIONS ......................................................... 58
6.6 ALARM LEVELS AND SPECTRAL BAND WIDTH SPECIFICATIONS ............................................... 60
6.7 CASE A - GENERAL EQUIPMENT WITH COG TOOTH OR BLADE BEARINGS .................................... 60
6.8 CASE B - GENERAL EQUIPMENT LIKE FLAT STRENGTHENING PLATES WITHOUT COG TEETH OR BLADES. ..... 61
6.9 CASE C - GEAR BOX, HIGH FREQUENCY POINTS WITH A KNOWN NUMBER OF TEETH ........................ 62
6.10 CASE D - GEAR BOXES, HIGH FREQUENCY POINTS WITH AN UNKNOWN NUMBER OF TEETH ................ 62
6.11 CASE E - MEASUREMENT POINT FOR THE ROTOR ROD PASSAGE FREQUENCY IN INDUCTION MOTORS ....... 63
6.12 CASE F - LOW FREQUENCY MEASUREMENT POINT FOR THE DETECTION OF ELECTRIC FREQUENCY.......... 63
6.13 CASE G - SPECIAL EQUIPMENT .......................................................................... 64
6.14 THE DETECTION OF HIGH FREQUENCY IN THE BEARING CONDITION DIAGNOSTICS.......................... 65
CHAPTER 7 74
7.1 INTRODUCTION ........................................................................................... 74
7.2 THE PRINCIPLES FOR CORRECT MOUNTING OF VIBRATION TRANSDUCERS ................................... 74
7.3 SELECTION OF MEASUREMENT POINTS ON THE EQUIPMENT ................................................. 77
7.4 EFFICIENT TRACING OF MONITORING ROUTES ............................................................. 79
7.5 DEFINITION OF MONITORING PRIORITIES ................................................................... 80
CHAPTER 8 82
8.1 INTRODUCTION ........................................................................................... 82
8.2 SELECTION OF THE OPTIMAL PARAMETER FOR THE LOW FREQUENCY MEASUREMENTS (ACCELERATION,
VELOCITY AND MOVEMENT) ............................................................................ 82
8.3 REQUIRED EQUIPMENT FOR LOW FREQUENCY ANALYSIS .................................................... 83
8.4 BEARING EVALUATION IN THE EQUIPMENT WITH LOW SPINNING VELOCITY. ................................. 86
8.5 SPECIFICATIONS FOR THE ALARM LEVELS IN THE SPECTRAL BAND FOR THE LOW SPINNING VELOCITY EQUIPMENT
....................................................................................................... 87
CHAPTER 9 88
9.1 INTRODUCTION ........................................................................................... 88
9.2 DEMODULATION BASIC PRINCIPLES ........................................................................ 88
9.3 FUNCTIONS OF THE CSI DEMODULATOR 750 .............................................................. 89
9.4 EXAMPLE OF DEMODULATOR 750'S USE ................................................................... 91
9.5 CONCLUSIONS ............................................................................................ 92
CHAPTER 10 95
10.1 INTRODUCTION ......................................................................................... 95
10.2 MAINTENANCE INDICATORS .............................................................................. 95
10.3 CONCLUSIONS........................................................................................... 96
CHAPTER 11 99
11.1 INTRODUCTION ......................................................................................... 99
11.2 VIBRATION ANALYSIS REPORT ........................................................................... 99
11.3 REPORT OF THE RESULTS OBTAINED .................................................................... 100

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CHAPTER 12 106
12.1 INTRODUCTION ........................................................................................ 106
12.2 PRECISION ALIGNMENT ................................................................................. 106
12.3 PRECISION BALANCING ................................................................................. 107
12.4 BASES AND ANCHORING ................................................................................ 107
12.5 DOCUMENTING THE PRECISION CORRECTIONS ........................................................... 109
12.5 DOCUMENTING THE PRECISION CORRECTIONS ........................................................... 110
12.6 FINANCIAL SAVINGS .................................................................................... 110
CHAPTER 13 113
13.1 INTRODUCTION ........................................................................................ 113
13.2 MANAGEMENT SUPPORT AND PLANT'S CULTURE ......................................................... 113
13.3 PROGRAM ORGANIZATION .............................................................................. 114
13.4 PREDICTIVE MAINTENANCE TECHNOLOGIES.............................................................. 114
13.5 PROACTIVE MAINTENANCE .............................................................................. 114
13.6 TRAINING DEVELOPMENT ............................................................................... 115
13.7 MAINTENANCE INDICATORS ............................................................................. 115
13.8 EXAMPLES OF THE EVALUATION QUESTIONS. ............................................................ 115
CHAPTER 14 117
GLOSSARY ................................................................................................... 117
CHAPTER 15 123
ANNEXES .................................................................................................... 123

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CHAPTER 1
Definition of the effective
organization of the personnel
assigned to the Preventive-
Predictive Maintenance (PPM).
1.1 Introduction
The decision to establish a Preventive-
Predictive Maintenance System in the plant is
the first stage in obtaining the total cost of
the maintenance and substantial
improvements in the efficiency of the
production process.
There are a great number of plants today,
which operate successfully with the
predictive maintenance system. However,
there are factories that have failed during
the first three years of the operation, coming
to the point of abandoning completely the
Predictive maintenance systems.
The primary causes of the failure are the lack
of programs' formal, clear objectives and
goals before its initiation.
The primary purpose of the first chapter is to
give to the reader general rules for the
definition of the objectives and goals. The
reader will also learn about the general bases
for personnel selection, which will form the
Predictive Maintenance Group and the
manner in which they will be organized.
1.2 Conditions for success
A successful Preventive-Predictive
Maintenance System should be able to
quantify obtained advantages. This could be
achieved only if the program was established
appropriately, if the adequate predictive
maintenance techniques were used, and if an
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effective evaluation system of advantages is
put to use.
The success or failure will depend directly
from the effort realized in the beginning of
the program's implementation.
An appropriate implementation of a
Preventive-Predictive Maintenance System
should include the following elements:
- Clearly defined objectives and goals
- Recording system of advantages obtained
- General support
a) Human resources
b) Financial resources
c) Long term planning
- Effective organization of the PPM personnel
- Dedicated personnel which is independent
from the plant's operations
- Various persons' blend of experiences
- Teamwork
- Training strategies
a) Training program
b) Continuous training
- Efficient procedures for the collection and
analysis of the obtained data
- Practical work
a) Precision alignment
b) Precision balancing
- Implementation of precision corrections
- Establishment of standards of acceptance for
suppliers
- Perseverance
- Communication programs
- Obey for the main PPM
In the following chapters most of these
elements will be explained in detail. With
respect to this chapter, we shall concentrate
on the definition of the objectives and goals
and on the efficient organization of the
personnel that will be assigned to the
Preventive-Predictive Maintenance system.
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The predictive maintenance uses various
techniques; however, we shall refer only to
the analysis of vibrations program because it
is the technology with the fastest
implementation and it provides the best
investment returns.
1.3 Definition of Goals and Objectives
Every constructive action comes from a well-
established purpose. The Preventive-
Predictive Maintenance System's goals and
objectives should be developed and adopted
by the work groups in the operative areas in
coordination with the plant's general
advisors.
It is important to remember that the PPM
should not be an ideal excuse for the
purchase of sophisticated equipment in the
area of data collection and analysis, or the
justification for employing a numerous group
of people in charge of taking data from
various types of equipment.
The real purpose of a PPM is to minimize
equipment failures, maintenance costs and
the unplanned stoppages. The PPM should
also try to increase the efficiency and the
quality of the plant's product.
This will be achieved through the periodic
monitoring of the equipments' mechanical
condition, equipment and process' efficiency,
as well as a close observation of other
parameters, which define the plant's
operational conditions.
This manual focuses on the mechanical
conditions of the equipment through the
vibration analysis.
The objectives and goals vary from plant to
plant; however, as the information pertinent
to the actual situation is needed, it will be
necessary to determine the conditions for the
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most important maintenance indicators, such
as:
- monthly maintenance cost
- maintenance cost per production unit
- time percentage of extra labor
- plant's availability
- monthly electric consumption
- total cost of parts' stock
- etc.
In chapter 10, these indicators will be
explained in detail. As the reference data
pertinent to these indicators will be used to
evaluate the PPM, the following data will be
the minimum required: maintenance
personnel's labor cost and maintenance
personnel's extra time.
As in some plants the adequate observation of
the indicators is not correctly recorded, the
calculation phase of the reference values
causes great difficulty in the implementation
of the PPM because it is necessary to obtain
the information generated in the
administrative files.
The long-term objectives of the Preventive-
Predictive Maintenance system are:
- Eliminate unnecessary maintenance
- Minimize the production loss caused by
equipment breakdowns
- Reduce the inventory of replacement parts
- Increase the process efficiency
- Improve quality production
- Prolong the utility of different components
of the factory
- Increase the production capacity
- Reduce the maintenance total cost
- Increase the factory's total profitability
All the objectives previously mentioned are
measurable; consequently, value references
should be acquired before the implementation
of the PPM and realistic goals should be
established for each element.
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1.4. Management's support
The implementation of the Preventive-
Predictive Maintenance System involves the
capital investment in taking data and
acquiring equipment, as well as in personnel.
In order to implement the PPM and to reach
its goals, it is necessary that management
make a commitment to provide the necessary
resources.
The management should also facilitate the
communication ties between different
departments in order to promote the
exchange of necessary information for the
registration and calculation of maintenance
indicators. In some cases, the information is
not found directly in the maintenance
department, for example: the energy cost,
the total processed products, etc.
It's important to mention that in the factories
that failed in its Predictive Maintenance
systems, the management provided for the
initial purchase of measuring equipment.
However, the necessary resources were not
invested into the PPM staff, the personal
training and the independent consultants;
and they are all necessary components in the
successful implementation of the program.
One of these programs, with deficient
administration, will fail within the first year.
Programs have failed because the
management was not informed correctly of
the PPM way of operation.
It is essential that the manager know that
the most important benefits are obtained in
the long term. The absence of this
information could make the manager
pressure the personnel because of the
investment and lack of results.
An important aspect to consider is the fact
that during the first year of the system's
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operation, the personnel in charge will find
equipment with the most failures and
problems. These personnel will generate
corresponding reports for the solution of the
equipment problems.
After the first year of the system's operation,
the most serious problems will be completely
resolved, and the personnel's reports will show
few or no major corrective actions.
In order to realize initial corrective actions it
will be necessary to invest resources for the
solution of the problems. As an example we
can cite: precision balancing, precision
alignment, improvements in consolidation and
support mechanisms, hiring of independent
consultants, etc.
If one does not have a clear view of this
implementation stage, the management will
probably conclude that the program is not
succeeding in obtaining the benefits which
justify the assigning of major human resources
and an investment in additional technologies,
as are precision balancing and alignment.
1.5. Personnel in charge of the Preventive-
Predictive Maintenance System
All the successful Preventive-Predictive
Maintenance Systems dedicate full-time
personnel to form the PPM group. In some
cases, these groups cover various areas of the
plant, and in others, several factories at the
same time.
In any case, a successful PPM will need a
selected group of persons dedicated
exclusively to the tasks of predictive
maintenance in order to fully concentrate on
the achievement of goals and objectives
established at the beginning of the program.
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Even though some successful plants have
assigned part time personnel to these tasks,
this approach is not recommended. It is very
probable that due to an excessive workload,
the personnel cannot maintain the proper
monitoring frequency and equipment
analysis.
The continuity in monitoring and analysis is
critical for the success in a predictive
maintenance program.
It is important to remember that the
Predictive Maintenance Group will be the
plant's profit generating center from the
moment the system is implemented.
The factories that have implemented
successfully the MMP report production
increase from 10% to 30%, the typical cost
maintenance reduction from 25% to 50% and
the total profits increase of 50% in the most
favorable cases.
In all the factories that have successfully
implemented the PPM, it was noted that the
management has offered a great support,
which contributed to these results. Its
protagonist roll is based on the assignment of
economic and human resources to promote
the program's development. The
management also has the roll of a mediator
in the interaction between the maintenance
department (provider) and the production
(client) with the purpose of programming the
repair work in the most efficient way.
When we talk about World Class
Maintenance, we can only talk about an
organization with high proficiency in the
maintenance department and the precision
correction in equipment. In the beginning,
the precision corrections will take longer
than usual repairs.
However, the time invested is justified
because it increases the functional duration
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of equipment and decreases considerably the
vibration levels.
Due to the fact that the solution to equipment
problems requires an analysis before and after
the correction, we shall present the ideal
vibration analysis attributes as well as the
necessary qualities of the personnel in charge
of maintenance.
1.6. Ideal characteristics of a vibration
analyst
One of the most important attributes in
obtaining a success in a predictive
maintenance program based on a vibration
analysis will be an adequate selection of the
personnel who will be in charge of the project.
Even though there is very much information
about vibration analysis as well as programs
and seminars that facilitate the learning, it
will be important to select the adequate
personnel who will be in charge of the
program and which complies with the
following principles.
The ideal attributes of a vibration analyst are:
- A recognized leader
- Self-motivated
- Experienced in mechanical maintenance
- Skillful in verbal and written communication
- Decision taker
- With mechanical inclination
- Analytical
- Decisive
- Competent
- Willing to learning new techniques
- Skillful in computer use
- Focused on details
- Always looking for the cause
- Good observer
- Consistent in his work
- Capable in making propositions
- Gifted in abstract thinking
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- Dedicated in report generating tasks - Inclination for meticulous work

- High performer - High performer
- Consistent in follow-ups - Consistent follow-ups

The key characteristics in this person are: The correct selection of the personnel in
charge of the system will result in the
- Willingness to approach the task program's success, which implies the analysis,
- Willingness to learn follow-ups and precision corrections.

It is important to mention that the major
developments in technologies and training
programs are elaborated in the United States
and consequently an additional element
could be the proficiency in English.
However, this requirement should not be
absolutely indispensable.
1.7 Ideal characteristics of a person in
charge of maintenance
The complete success in the predictive
maintenance program will not only depend on
the vibration analyst, but also on the rest of
the team, such as: the management, the
person in charge of maintenance and the
production department.
The roles and responsibilities of every group
member, as well as their interrelation, will be
described in Chapter 2.

In the majority of successful predictive

maintenance programs, we find a person in
charge of maintenance who is responsible for
precision corrections and retro alimentation
to the vibration analyst regarding the work
done.

The person in charge of maintenance

collaborates with the vibration analyst from
the moment the system is implemented. As
he will have some similar responsibilities to
the ones of the analyst, their profiles will be
alike:

- Self-motivated
- Experienced in mechanical maintenance
- With mechanical inclination
- Analytical
- Decisive
- Competent
- Willing to learning new techniques
- Skillful in computer use
- Focused on details
- Always looking for the cause
- Good observer
- Consistent in his work

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IMPLEMENTATION PROCEDURE FOR A PREVENTIVE-PREDICTIVE MAINTENANCE SYSTEM BASED ON
VIBRATION ANALYSIS
Personnel Selection
Vibration Analyst
Evaluation of Analyst's
Diagnostic Ability
Vibration Analyst's
training program definition
Training in the use of the
instruments and Software
Selection of the monitoring
Chapter 1 and 2
Team who will consider the
d2
Priorities and Maintenance
Costs
Chapter 3
The technical data recording
of the equipment necessary
for the System
Chapter 3
Selection and identification of
measurement points
according to the
supplier
Optimal arrangement of
the data bases, space and
equipment to be recorded
in the Software
CHAPTER 1
Defining the parameters of
the Spectral Band Analysis
and Alarm levels for the
Critical Equipment
Chapter 6
Chapter 4
Selection of the appropriate
Transducers for each equipment
and Particular Measurement
point
Chapter 5 Chapter 7
Data generation in the
Predictive Maint. Software:
- Space
- Equipment
Chapter 5 - Measurement Points
- Analysis parameters
- Alarm levels
- Typical failure frequency
- External system
according to the
structural
organization of the
software Efficient selection of
Monitoring Routes and
the definition of monitoring
intervals
Chapter 7
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BASED ON VIBRATION ANALYSIS
Analyst's/Collector's
Routing responsibility
according to the monitoring
duties
Data collection from
equipment
ї Activated alarms Yes
in the field?
No
Computer registration
by the Analyst/Collector
Printing of an
Exceptional report
Printing of the "Alarm
report" according to
priority
1 2
CHAPTER 1
2
1 Elaborate a report
No Is it an urgent
informing about the problem?
present situation
Analyzing the wave
spectra and Yes
shapes obtained
according to the Reduce to one half the Write a report with
list of the "Alarm Monitoring interval Recommendations and
priorities" Steps for the solution
Recording of the
Additional spectra
with an increased Schedule the stoppage
resolution, if necessary 2 according to the
,to facilitate the recommendations
diagnostic, data and make the repair
collection of the phase, No Is there enough
resonance testing, etc. Information to make
a conclusion?
Monitoring the initial
states to see whether
there are improvements
Yes
Elaborate Diagnostics
No Problem
1 resolved?
Compare results with Yes
those of the Expert System
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CHAPTER 2 1. He will be responsible for the acquisition

Definition of the members' Roles
and responsibilities in the
Preventive-Predictive
Maintenance System
2.1 Introduction
In Chapter 1, we described the importance
of the measurable objectives and goals in a
Preventive-Predictive Maintenance System,
as well as the importance of the ideal
attributes of the vibration analyst and the
person in charge of maintenance. In this
chapter, we shall focus on describing the
roles and responsibilities of each member of
the group who will be responsible for the
PPM implementation and operation.
2.2 Formation of the Predictive
maintenance group
The Preventive-Predictive Maintenance
System involves each one of the following
employees in the formation of the working
group:
Plant's Maintenance Director
Vibration analyst
The person in charge of maintenance
Technical Director of the group
of all the instruments and computer systems
necessary for the analyst and the person in
charge of maintenance.
2. He will collaborate with the production
personnel to define which of the plant's
equipment will be observed and to establish
its monitoring intervals. The criteria for the
equipment selection will be presented in
Chapter 4.
3. He will be responsible for the
arrangements necessary for the analyst's
and technician's training. He should be
informed of all the seminars and
conferences available during the whole
year.
4. In agreement with the analyst, he will
define the equipment's codification in order
to incorporate it into the system.
5. In collaboration with the analyst, he will
define the Spectral Band Alarm Levels for
all the equipment in the system (see
chapter 6).
6. The Maintenance directors, the analyst
and the personnel of the Systems
department will define the adequate
procedures to make a back up (reserve)
copy of the stored information.

Each member of the group will fulfill his 7. He will determine what equipment will
roles and responsibilities in such a way that be included in the Preventive-Predictive
working together the group will make the Maintenance System, and the technologies
program successful. that will be used. For this reason, he will
have to elaborate a schedule with
2.3 Plant's maintenance director deadlines, covering all the equipment to
which a predictive technology will be
The plant's maintenance director will be a applied.
partial member of the Predictive
Maintenance group due to his additional 8. He will prepare and publish monthly
responsibilities in the organization. Preventive-Predictive Maintenance System
However, he will have the following reports, including the description of the
responsibilities in the Work group: progress and successes achieved by the
Program. In order to do this, he should seek

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support from the analyst and the person
responsible for maintenance.
9. He will make sure that the plant's
maintenance personnel know the objectives
of the PPM and that he will create the
necessary seminars to improve the
maintenance, especially in precision
correction and precision alignment.
10. He should be subscribed to specialized
reviews in Predictive Maintenance in order
to be informed about technological
improvements and new ways of finding
potential problems in equipment.
11. He should be in contact with the
Technical Section in order to be informed
about available classes and seminars for the
members of the Preventive-Predictive
Maintenance system.
12. He should have the knowledge about
precision alignment, precision balancing,
basic vibration analysis and the content of
the Preventive-Predictive Maintenance
System that is used at the plant.
13. He should elaborate the acceptance
specifications for the suppliers' work with
respect to alignment and balancing, as well
as the acceptance criteria for new
machines.
2.4 Vibration analyst
The vibration analyst is a group member
who will be working full time at his
responsibilities:
1. Maintaining and updating the databases
generated for the vibration analysis:
a. The study of the equipment manuals and
their assembling diagrams in order to have
all the necessary information for the
introduction of new equipment into the
system.
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b. Selection and measurement marking of
the equipment included in the system.
c. Incorporate equipment into the system
with the person responsible for the
maintenance.
d. To establish in collaboration with the
maintenance director the alarm levels for
the spectral band for each type of
machines, which should be included in the
system. This information should be
included in the computer system (see
chapter 6).
e. Elaborate and arrange in the most
efficient way the monitoring routes in order
to record the equipment's vibration (see
chapter 7).
2. He will take vibration data from the
equipment and he will write special reports
to determine which equipment needs a
detailed analysis based on the obtained
spectra. He will analyze present and past
readings in order to have a complete view
of the vibration record and be able to
predict potential failures.
3. He will prepare the necessary "action
reports" and generate work orders for the
corrective maintenance. He will turn in this
report and the work order to the
maintenance coordinator indicating
potential problems. A model report is
found in chapter 11.
4. He will readjust the equipment's
monitoring schedule according to the
changes that take place and he will shorten
the period between monitoring sessions for
the equipment that presents signs of
deterioration.
In the equipment that presents no
significant data, he will extend the period
between monitoring session; but only, if and
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when the equipment in question is not
critical for the production.
5. He will contact the maintenance
director, the members of the technical
section or an independent consultant when
he needs a second opinion regarding the
vibration analysis.
6. Together with the person responsible for
maintenance, he will file maintenance
supervisor's reports that contain the
description of the work done as was
recommended by the analyst or technician.
7. He will collect the information from
various sources regarding the savings and
benefits in order to annex it to the records.
This information will be necessary in the
elaboration of the director's monthly
maintenance reports. The documentation
about achieved goals will be a justification
for more support from the plant's
management.
8. He will add more equipment to the
system when he feels that it is necessary to
take readings from additional equipment.
9. He will take samples from the gearboxes
for the Ferro graphic analysis from the
equipment whose vibration levels are
abnormal, especially when the gearing
frequency amplitudes increase. The results
from the oil analysis will confirm the
interpretation of the spectral vibration.
10. He will use other preventive
maintenance techniques applicable to
equipment's condition. These approaches
could be obtained from independent
consultants if there is a lack of equipment
or necessary experience. It is important
that the analyst is familiar with different
predictive maintenance techniques in order
to use them adequately when they are
needed.
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11. He will take classes and take part in
training seminars in vibration analysis. He
should also attend conferences and
expositions where the latest market
achievements in instruments and advanced
analysis techniques are demonstrated.
12. He will need the necessary knowledge
in precision alignment and balancing. He
will need to realize at least one precision
alignment per month. The same should be
done regarding precision balancing with all
the equipment that needs it. He will record
"influence coefficients" obtained during
balancing in order to save time in future
balancing with the same equipment. The
updating of this information will be his
responsibility.
13. He will need to check the vibration
levels of the new and repaired equipment
to ensure that it complies with
specifications that were given to the
supplier.
14. He will need to write a monthly report
with a resolved case that had a positive
impact for the plant by decreasing the
maintenance cost and/or has achieved a
significant decrease in vibration levels. In
this report, the information should contain
the total vibration tendency of all the
equipment that is monitored at the plant.
This indicator is crucial in the observation
of the precision corrections.
2.5 The person in charge of maintenance
A person in charge of maintenance is
included in the predictive maintenance
group because it will be necessary to do
precision corrections and these corrections
will be a port of his responsibilities.
The number of members of this department
will depend on the plant's size.
The responsibilities of this department
include:
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1. The department will be in charge of
coordinating, in collaboration with the
vibration analyst, the precision balancing at
the plant. He should participate in the
balancing tasks performed by the analyst in
order to obtain the lowest vibration levels.
2. The department will be responsible for
the precision alignment of the most critical
equipment; the personnel should be at least
trained in the modern techniques of
precision alignment, either with the
reversed indicators or with laser based
instruments.
3. It will file the records of all the
alignments in order to have them available
for future alignments.
4. It will file the corresponding information
in par with the equipment's operation
before and after the precision alignment in
order to calculate energy savings. These
results will justify the acquisition of the
latest technologies in alignment, such as
the laser method.
5. It will be responsible for ensuring the
quality of repairs done by independent
companies and it should ask for the
precision balancing and precision alignment
certificates when outsourcing does the
work.
6. It should supply the vibration analyst
with the most relevant information about
the repairs. If necessary, a group member
should ask for analyst's help during repairs
in order to resolve collaboratively the most
critical equipment problems.
2.6 Technical Department
The technical department of will be
an additional complement to the predictive
group. Even though the technical
department will not be an active member in
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the every day activities, it will have staff
responsibilities, which will have a positive
impact on the program's success:
1. They will elaborate implementation
strategies for each predictive technique
that will be implemented in the , as
is the case of this manual. These strategies
will have the essential objective to
facilitate the implementation and operation
of various predictive techniques applicable
to the teamwork.
2. They will present to the Director of
every plant the elaborated strategies for
each technique.
3. They will develop vibration analysis
classes and seminars for the whole group in
order to train the plant's personnel. The
advantage of these seminars is to unify the
group's criteria.
4. They will help directly when confronted
with equipment vibration problems using
their own experience or the help from
another plant, as well as with the
independent consultants in the field.
5. During the implementation stage, they
will offer assistance to all the plants that
need it to facilitate the process. For this
purpose, the technical department will be
able to seek assistance from independent
specialists.
6. They will maintain the plant's personnel
informed about new technologies in the
market, as well as about the most recent
and innovative techniques for resolving
problems.
7. They will evaluate instruments, services
and analysis techniques of various suppliers
to achieve group standardization. For such
effect, they should be trained in various
techniques of predictive maintenance, as
are vibration, thermography, oil analysis,
ultrasound, etc.
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The program's success or failure will be seen

8. They will define the world-class
evaluation processes, which will be applied
to all the company plants. Thanks to this
approach, it will be known which plants in
the company are similar to Benchmark's
position in order to apply similar strategies
in the rest of the plants.
9. They will apply the world-class
evaluations in the plants that have the
predictive maintenance system in operation
for at least six months.
sooner or later with the maintenance
indicators, pay off indicators and plant's
profitability. Even though the actual
instruments are sophisticated and provide
great advantages in the analysis tasks, they
will not resolve communication problems
that could exist among the members of the
Predictive Maintenance group and the final
user, the production department.
The relation between the integral parts of
the group is shown in the diagram 2.1.

2.7 Conclusions

All the previously mentioned parts of the

Preventive-Predictive Maintenance System
should work in close collaboration and as a
whole. The common goal of this group is
the successful implementation and
continuous operation of the Preventive-
Predictive Maintenance System.

Each integral group should accomplish its

responsibilities previously assigned to
achieve the common goal. These
responsibilities can vary according to the
maturity phase of the system and the
number of plant members. However, this
approximation will be a good start to ensure
the program's success.

It is important to remember that one should

not temper (politicize) with the system, as
it is the essential element for the successful
realization of the Preventive-Predictive
Maintenance program. The previous
comment refers to the necessity to
eradicate all types of politics from the
fundamental activities of the program. This
project requires that all the members of the
group focus positively their energy in order
to facilitate the system's implementation
and continuous operation.

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STAFF
Technical Department
Maintenance
Management

Vibration analyst Person in charge of

Maintenance

Diagram 2.1 Operation chart of the Preventive-Predictive Maintenance System.

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CHAPTER 3
Training: Definition, Planning
and Scheduling of the training
requirements
3.1 Introduction
To be successful in the implementation
stage of the Preventive-Predictive
Maintenance System, the members of the
group will be required to have consolidated
knowledge about the equipment's
operational dynamics in the Preventive-
Predictive Maintenance System and about
the instruments used to collect and analyze
vibration data.
For the plants that incorporate for the first
time a Preventive-Predictive Maintenance
System, it will be fundamental to define,
plan and schedule the implementation of
the minimum requirements necessary for
the program.
In this chapter, the training needs for the
initial stages of the program's
implementation will be defined, and a
proper scheduling will be presented to
promote the personnel's knowledge in par
with the program's development.
An evaluation questionnaire (test) for the
determination of the personnel's proficiency
level is annexed to this chapter in order to
determine the training needs in vibration
analysis. The design of this questionnaire is
based on the selection of one answer in
order for the results to be calculated by
adding all the positive answers. The final
score will define the personnel's training
needs for the vibration analysis.
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3.2 Minimum training requirements
The vibration analyst should have at least
the following knowledge:
-Basic level of Vibration analysis
-Personal computer use, Windows and
various text processor software.
-Data analyzer/collector's basic functions
-The use and configuration of the
Preventive-Predictive Maintenance System.
To obtain a better training result, it is
recommended to plan the training stages
according to the previously established
schedule. It is possible that one already has
the necessary knowledge in vibration
analysis and the computer use.
If one already knows how to use computers,
this stage can be eliminated from the
training plan. If one already has some
experience and knowledge in the vibration
analysis, he/she will need to answer the
questionnaire annexed to this chapter to
define his/her training needs. Depending
on the results obtained in the
questionnaire, the personnel should be
scheduled for any of the three following
courses:
Basic level in vibration analysis
Intermediary level in vibration analysis
Advanced level in vibration analysis
The suggested content for each of these
courses is presented bellow and an
independent consultant or a specialized
enterprise in this field of training could
prepare it.
3.3 Basic level in vibration analysis
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This course will have the following content: The maintenance director will be very
important in the promotion of the
1. Basic vibration principles continuous training program in order to
-amplitude obtain the maximum results. The number
- phase of problems resolved at the plant will
- frequency depend directly on the knowledge in
diagnostics and problem solving acquired by
2. Different types of measuring instruments the group.

3. Different types of vibration sensors

3.4 Intermediate level in vibration
4. Resonance analysis

5. Most common failure diagnostic, using The content of the intermediary level
phase spectra: course:
- unbalance
- lack of alignment 1. Analysis of the wave shape
- bent rotors
- bearing failure 2. Analyzer's advanced functions:
- loose machine parts
- belt and pulley problems - synchronous averaging
- friction - negative averaging
- gear box - averaging by tracking ordinates
- polar diagrams
6. Vibration tolerance levels - demodulation technique
- current's spectral analysis
In general, this is the material that is
required for the personnel's initiation into 3. Electric problems
the vibration analysis. The knowledge - induction motors
acquired in the first course will be used in - direct current motors
detecting the most common failures at the - synchronous motors
plant.
4. Gear box
However, there will be cases of defective Identifying lateral bands
equipment that will require a more use of demodulation
advanced, analyst's knowledge. For this
reason, an intermediary course on vibration 5. Bearings
analysis is recommended six months after finding lateral bands
the beginning of the system's initiation. use of the wave shape
demodulation use
If a complex vibration problem is presented
during the first 6 months, it is Normally, the knowledge acquired in this
recommended to contact an independent course will be applicable to the existent
adviser in order to find the solution. The technology at the beginning of the
plant's personnel will learn the manner in Predictive Maintenance. The advanced
which the problem was resolved, reinforcing level course in vibration analysis, that will
the knowledge of the group. be seen bellow, will require the acquisition

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of advanced technology in analysis and
special computer packages.
3.5 Advanced level in vibration analysis
This course is recommended for the plants
that have solidified Predictive maintenance
programs in which they have obtained
favorable results in maintenance. However,
the maintenance group has on occasions
faced problems that it could not resolve
with the knowledge acquired in the first
two courses.
To resolve complex problems in vibration
analysis, it is recommended to acquire
multi-channel analysis technology, which
could be used to localize complex
equipment failures.
Once the plant has come to this stage of
maturity, it is recommended to take an
advanced course with the following content:
1. Course in multi-channel analysis
2. Study of transitory events
3. Modal analysis
4. Use of ODS (Operational deflection
shape) to observe the vibration mode of an
equipment in a computer system.
5. Relative phase between two measuring
points
6. Transference function
7. Coherence
It is important to mention that on occasions
it is not necessary to pursue the
specialization to this point, especially when
there are consultants who can resolve these
specific problems. However, in this case,
additional technology can be acquired
according to the specific needs regarding
some old equipment problems.
It is recommended that the
plants have among their staff at least two
persons with this level of proficiency in
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order to resolve the most complex
problems. Even though it is possible to
have only one specialist in a large plant
with the aforementioned qualifications.
3.6 Training in the use of instruments and
the Predictive Maintenance System
With respect to the use of the data
analyzer/collector, as well as in the use and
configuration of the Predictive Maintenance
system, the supplier of the instruments
according to the stipulated purchase clauses
should teach the latter.
However, it is amply recommended to hire
an independent consultant to initialize the
system, defining the alarm levels for each
type of equipment and facilitating the
critical equipments' configuration stage in
the system.
Additionally, this consultant could realize
the first analysis of the equipment that
could be a review and practice of the
acquired knowledge in the Basic level of
vibration analysis by the Predictive
Maintenance Group.
Among the basic functions of the vibration
collector/analyzer equipment CSI model
2115, we can mention the following:
Data collection in programmed routes
Outside of the route configuration mode
Information transference
analyzer's routing load
PC data loading
analysis functions
real time spectrum
wave shape in real time
global value vs. time
peak and phase monitoring
The functions and configurations of the
Predictive Maintenance system CSI Master
Trend include:
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data creation archive
equipment configuration
measurement points configuration
assignation of analysis parameters
assignation of spectral band alarms
configuration of expert systems
report generation
spectral display
communication with the analyzer
data base maintenance
information printing
frequency failure display
programs for typical frequency calculation
in bearings, gears and various types of
failure.
Program for recording equipment failure
information and follow-ups.
and others.
The estimated time for the training in the
use of this technique is approximately 10
days, either at the plant or at the supplier's
installations. In case of the training at the
plant, the information recording will be
swifter because the examples used will
include the plant's equipment.
3.7 Vibration analysis questionnaire
As was previously mentioned in this
chapter, the primary objective of this
questionnaire is to evaluate the actual level
of knowledge of the Predictive Maintenance
Group members in order to define the initial
training needs in vibration analysis.
The questionnaire is presented in Table 1
and the answers in Table II. On the right
side of Table I, one needs to mark one point
for each correct answer and o points for
each wrong answer.
The first 25 questions are used to define the
basic level of knowledge in vibration
analysis. The questions 26 through 30 deal
with a more complex subject matter and
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they will serve as an evaluation tool for the
members' capacity to make an advanced
diagnostic. Based on the results from the
first 25 questions, we conclude:
a) If the total score is less than 17 in the
first 25 points, the questions 26 through 30
do not need to be answered. It is
recommended to take the Basic Vibration
course to acquire the content, which was
suggested earlier in this chapter.
b) If the score is higher than 17 in the first
25 questions, and the score for the
questions 26 through 30 is higher than or
equal to 4, it is recommended to take a
course in Advanced Vibration.
3.8 Additional training
The original goal of the Preventive-
Predictive Maintenance System is to,
remembering the content of chapter 1,
increase the availability of the equipment
and their duration. The diagnostic of the
equipment's problem is only one necessary
stage in the achievement of this goal.
The implementation of the precision
correction to resolve the vibration
problems, is another necessary stage on the
path to plant's operational excellence. For
this motive, the personnel of the Predictive
Maintenance Group will need to have
necessary knowledge in order to support the
maintenance personnel in the correction
tasks.
For this reason, the personnel of this group
should be trained in the following areas:
Multi-plane balancing
Precision alignment
In case the personnel of the group do not do
the balancing, it will be necessary to know
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the balancing techniques in order to solicit
the maximum quality from the suppliers. In
chapter 13, we shall see acceptable
balancing criteria.
In case of the precision alignment, the most
usual arrangement is that each plant has its
personnel for these tasks. For this reason,
special precision alignment techniques
should be performed, such as alignment
with the inverted indicators or laser
alignment. The selection of a particular
technology will depend on plant's profile.
The laser system is easier and has a greater
precision.
On the implementation schedule for the
Preventive-Predictive Maintenance System,
it is recommended to program courses on
these topics for the Predictive Group three
months after the system is initiated.

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TABLE 1. VIBRATION ANALYSIS QUESTIONNAIRE

No. QUESTION ANSWERS Pts.

1 Which of the following elements will indicate __ a. phase

the vibration seriousness? __ b. amplitude
__ c. frequency

2 The vibration unit most used to measure the __ a. mils peak

residual unbalances in the equipment is: __ b. mils peak-peak
__ c. in./sec. peak

3 The most used vibration parameter to measure __ a. movement

the "health" level of an equipment with __ b. acceleration
spinning frequency ranges from 600 and 10,000 __ c. speed
rpm is:
4 The acceleration vibration is most commonly __ a. high frequencies
used to measure the vibration levels in the area __ b. low frequencies
of: __ c. none of the above

5 When an axle spins at 100 rpm the most __ a. stroboscopic lamp

suitable method to obtain the phase is: __ b. optic tachometer
__ c. the phase can not be
taken

6 The minimum recommended frequency for the __ a. 6 cpm (cp.)

use of the speed sensor, or seismic sensor, is: __ b. 60 cpm (cp.)
__ c. 6000 cpm (cp.)
__ d. none of the above
(cp.)

7 The movement (displacement) sensor is based __ a. superficial contact

on the principle of: __ b. no contact
__ c. variable air gap

8 The vertical and horizontal phases are set at 0 __ a. excessive unbalance

or 180° in a ventilator fit with pulleys when __ b. eccentric pulley
there is a problem concerning: __ c. misalignment (lack of
alignment)
__ d. none of the above

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No. QUESTION ANSWERS Pts.

9 When a rotor is unbalanced, the phase __ a. 0°

difference between vertical and horizontal __ b. 180°
positions should be: __ c. 45°
__ d. none of the above

10 Which of the following options is not __ a. lack of alignment

considered to be a cause of vibration: __ b. unbalance
__ c. resonance
__ d. all of the above

11 The phase value in the resonance peak in __ a. 180°

comparison with phase value before entering __ b. 45°
the resonance curve will be set at: __ c. greater than 180°
__ d. none of the above

12 If there is a unbalance and the spinning __ a. 9 times

frequency increases three times, theoretically, __ b. 3 times
the vibration will increase: __ c. 6 times
__ d. none of the above

13 The system's natural frequency will be __ a. its mass is increased

increased when: __ b. the spinning
frequency increases
__ c. its rigidity increases
__ d. none of the above

14 The rotors that operate at a higher than normal __ a. resonant motors

frequency are known as: __ b. semi-rigid motors
__ c. flexible rotors
__ d. none of the above

15 The shock test that is used to calculate the __ a. the second critique
resonance will help us determine: __ b. the third critique
__ c. the none bending
mode
__ d. none of the above

16 It is possible to distinguish between unbalance __ a. yes

and lack of alignment only with the analysis of __ b. no
vibration's global values.

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No. QUESTION ANSWERS Pts.

17 When the axial vibration is 50% greater than __ a. resonance

the radial vibration, the vibration's most __ b. unbalance
probable cause is: __ c. eccentricity
__ d. none of the above

18 When there is a looseness problem in a gear __ a. harmonic frequency

box, the typical spectrum will present: __ b. high vibration at 1X
rpm
__ c. harmonic multiples
of 1X
__ d. none of the above

19 If by loosening a screw in a motor that is in __ a. residual unbalance

operation, the vibration decreases; it is __ b. unstable leg
probable that the problem is: __ c. lack of alignment
__ d. all of the above

20 . If after 30 minutes of functioning, the __ a. residual unbalance

vibration of a screw compressor set at 1X and __ b. lack of lubrication
2X RPM increases considerably, the most __ c. lack of alignment
probable cause of this increase is: __ d. all of the above

21 If the axial phase readings, taken in the same __ a. lack of alignment

direction at each of the ventilator supports, __ b. unbalance
shows a 180° difference, then the most __ c. looseness
probable cause is: __ d. bent axle
__ e. none of the above

22 The instability originated by oil shaking in the __ a. high frequency

flat strengthening plates will cause vibration in __ b. very high frequency
the following range: __ c. sub-harmonic range
__ d. none of the above

23 At which of the following bearing failure __ a. roller failure

frequencies, the axle spinning frequency acts __ b. cage (box) failure
as a lateral belt: __ c. internal track
__ d. none of the above

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No. QUESTIONS ANSWERS Pts.

24 In case of a turbulence in a centrifugal pomp, __ a. high frequency

the vibration will be generated randomly in: __ b. blade's frequency
__ c. sub-harmonic range
__ d. none of the above

25 Will the gearing frequency be similar for each __ a. yes

pair of gears even if they spin at different __ b. no
frequencies?

TOTAL NUMBER OF
POINTS IN THE FIRST 25
QUESTIONS

26 The information acquired by the separation of __ a. the severity of

the lateral frequency bands (belts) in the gear's unbalance
gearing frequency will help us determine: __ b. the intensity applied
to the gear
__ c. which gear has been
severely damaged
__ d. none of the above

27 The best way to detect broken gear teeth is to __ a. mils

analyze the vibration wave in the following __ b. g's
units: __ c. in./sec.

28 Which one of the following frequencies will be __ a. slipping frequency

presented as lateral belts (bands) around the __ b. pole's passage
spinning frequency when there are loose rods frequency
in the rotor or an induction motor? __ c. frequency of an
electric line
__ d. rod's frequency in a
rotor
__ e. none of the above

29 Which one of the following electric problems in __ a. eccentric motor

induction motors causes pulsing and rhythmic __ b. loose stator
vibrations at the spinning frequency of the __ c. rotor rolling in short
motor: circuit
__ d. none of the above
__ e. all of the above

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30 Which one of the following averaging __ a. peak maintenance

techniques is used to obtain spectra in a __ b. negative averaging
variable velocity equipment? __ c. synchronous
averaging
__ d. following (tracking)
ordinates
__ e. normal with pre-
filter
__ f. none of the above

TOTAL SCORE OF THE

LAST 5 QUESTIONS

Important note: If there is a scoring card with less than 17 correct answers, the person
should not answer questions 26 through 30.

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TABLE II. ANSWERS TO THE TABLE I QUESTIONNAIRE

QUESTION # ANSWERS COMMENTS

1 b
2 b
3 c
4 a
5 b
6 d the minimum recommended freq. is 600 cpm
7 b
8 b
9 d the phase difference will be 90°
10 c
11 d the phase difference will be 90°
12 a
13 c
14 c
15 d the first critique is determined
16 a
17 d lack of alignment
18 c
19 b
20 c
21 d
22 c
23 d
24 c
25 a
26 c
27 b
28 b
29 d loose or cracked rods in the rotor
30 d

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CHAPTER 4
Criteria for the selection of the
critical equipment
4.1 Introduction
When a Predictive-Preventive Maintenance
System is implemented, one of the most
significant objectives is to minimize the
equipment failures in order to reduce the
number of unplanned stoppages and to
achieve the maximum availability of the
production plant. Besides this objective, it
is important to reduce the total
maintenance cost.
In order to achieve these goals from the
very beginning of the system's
implementation, it will be necessary to
identify the critical equipment for the
plant.
Once the objectives of the Preventive
Maintenance Group were defined, the next
step in the implementation of the system
will be make the correct selection of the
equipment which should be included in the
program.
There are various criteria for the selection
of the equipment that should be included in
the system. In this chapter, we shall define
them using the selection criteria for the
critical equipment, which is based on the
plant's importance of production and its
maintenance cost.
Both selection criteria will be important in
achieving the maximum results during the
first months of the program's operation.
It is not recommended to initiate the
program monitoring all the equipment that
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is installed and operating in the plant
because it would be wearisome for the
analyst who is just starting his analysis, and
his attention can be sidetracked to the
equipment that is not critical for the
process or the maintenance costs.
4.2 Selection procedure
In order to proceed to the selection of the
equipment with which the system will be
initiated, a list, which includes all the
installed equipment in the plant, should be
elaborated, and each one of them should be
classified in accordance to its priority in the
system. The table I, shows the order in
which the plant's equipment should be
prioritized.
The list can be elaborated in a data base
package and afterward a priority list should
be made. For the elaboration of the
general lists of the equipment, it is
recommended to have the plant's layouts at
hand. It is very easy to omit equipment or
components while elaborating the list;
therefore, all the precautions should be
taken to ensure that all the equipment that
affects the production and its costs is
included on the list.
To determine the priorities according to the
production and costs, one should take into
account the following principles:
4.3 Priority 1, Very critical equipment
PRODUCTION PRIORITY
On this list should be included all the
equipment which has to be in operation for
a continuous production. In other words,
the loss or failure of any of them would
result in a total stoppage of the plant or its
production line, causing a total loss of
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production during a major period of time,
12 hours.
COST PRIORITY IN MAINTENANCE
With respect to maintenance costs, the
equipment whose repairs and maintenance
are excessively high will be included in this
group.
We shall include in this category the
equipment whose parts or components need
to be ordered with great anticipation
because of the prolonged delivery time or
the need for special parts, even when this
equipment does not represent a loss in
production when they are idling for the sake
of repairs.
Summarizing, there is equipment whose
costs of repairs are very low, however the
fact that these machines idle has a great
impact on the production, as can be the
case of a small lubrication pump of a
reducer or a turbo compressor.
On other hand, there will be situations in
which some teams will not cause a
production stoppage; however, their repair
costs and maintenance will be very
elevated, lowering the company's profits.
Consequently, it will be important to take
into account both criteria for the
classification of critical equipment that
should be included in Priority 1.
In this priority section, we can include as
examples: furnace components, mills and
cement plants' crushers.
4.4 Priority 2, Critical equipment
PRODUCTION PRIORITY
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All the equipment that at the moment of a
failure has a negative impact of more than
30% of the plant's production should be
included on this list.
If there are various production lines, each
one should be considered as a separate
plant.
COST PRIORITY IN MAINTENANCE
For the evaluation of the critical equipment
with respect to maintenance costs, one
should include the equipment with high
maintenance costs, or the equipment that
has required frequent maintenance
interventions caused by a design problem or
the tasks performed. It will be necessary to
review the equipment record to establish its
priority.
4.5 Priority 3, Equipment with normal
priority
PRODUCTION PRIORITY
In this selection will be included the
equipment which does not have a great
impact on the production if it stops
functioning. A typical example would be
redundant systems, or the ones that have
replacements, which have the so-called
"stand by" status.
However, this equipment will have a
considerable maintenance costs. The
equipment that could be repaired in less
than one hour could also be considered as
normal priority.
COST PRIORITY IN MAINTENANCE
With respect to maintenance costs, one
should classify as normal priority the
equipment that has relatively normal
maintenance costs, and also the equipment
that is repaired by independent personal.
For example, a screw compressor which has
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a redundant system and whose repair would Critical (Priorities 1 and 2) during the first
be provided by its supplier. six months of the system's operation. This
way, the maximum investment return
efficiency will be realized.
4.6 Priority 4, Equipment with low
As the program matures, the equipment
priority
that was classified as Priority 3 and 4 will
be annexed.
In this group should be included the rest of
the plant equipment which has an impact on
The Predictive Maintenance Group will have
the production and/or maintenance costs.
to scrupulously review the initial list that
includes all the plant equipment, and it
It is necessary to make an evaluation in
should courteously involve the members of
order to determine, according to the
the production and maintenance in this
equipment, the convenience of including it
process. The more information one has
in the monitoring list. In some cases, the
about the maintenance and repair time, the
replacement costs are smaller than the
easier the classification task will be.
annual costs required for the monitoring of
the equipment in this priority section.

There is equipment that operates under the

status of preventive maintenance, and
there might also be equipment that
operates till it brakes down. This does not
imply that no sufficient attention has been
dedicated to it.

Typical examples of this equipment are

cooling ventilators of some frequency
converters or direct current converters. In
case some of these little ventilators
suddenly stop, the panel's temperature
monitoring system will send a warning on
time and a stoppage could be prevented
with another cooling method.

This is only an example; the best selection

criteria will depend on the plant's working
profile.

4.7 Conclusions

To achieve a successful implementation of

the Preventive Maintenance System, the
efforts need to be focused on the
equipment catalogued as Very critical or
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Dirección de Tecnología

TABLE 1. PRIORITY ASSIGNATION OF THE PREDICTIVE MAINTENANCE SYSTEM

POSITION EQUIPMENT CODE SECTION PRODUCTION COST PRIORITY
PRIORITY
PRIORITY 1, VERY CRITICAL FOR THE PLANT PRODUCTION
1 VERY CRITICAL VERY CRITICAL
2 VERY CRITICAL CRITICAL
3 VERY CRITICAL NORMAL
4 VERY CRITICAL LOW
PRIORITY 1, VERY CRITICAL BECAUSE OF THE VERY HIGH MAINTENANCE COSTS
5 CRITICAL VERY CRITICAL
6 NORMAL VERY CRITICAL
7 LOW VERY CRITICAL
PRIORITY 2, CRITICAL FOR THE PLANT PRODUCTION
8 CRITICAL CRITICAL
9 CRITICAL NORMAL
10 CRITICAL LOW

PRIORITY 2, CRITICAL BECAUSE OF THE HIGH MAINTENANCE COSTS OR FREQUENT STOPPAGE

11 NORMAL CRITICAL
12 LOW CRITICAL

PRIORITY 3, NORMAL PRIORITY INCLUDES REDUNDANT MACHINES AND/OR WITH MODERATE MAINTENANCE COSTS

13 NORMAL NORMAL
14 NORMAL LOW
15 LOW NORMAL

PRIORITY 4, LOW PRIORITY FOR THE PRODUCTION AND LOW MAINTENANCE COSTS
16 LOW LOW

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Technology

SUGGESTED EQUIPMENT FOR IMPLEMENTATION IN THE PREDICTIVE MAINTENANCE

SYSTEM

PRIORITY TRITURATION QUANTITY

1 PRIMARY CRUSHER 1
1 SECONDARY CRUSHER 1
1 VIBRATING SIEVE 1
1 STACKER 1
1 RECLAIMER 1

GRINDING (RAW MATERIALS AND CEMENT):

2 MILL TRANSMISSION 2
2 SEPARATOR'S TRANSMISSION 2
2 SWEEPING IDF 2

CALCINATION:
1 KILN TRANSMISSION 1
1 TRANSMISSION COOLER GRATE 3
1 CLINKER CRUSHER 1
2 CLINKER COOLER FANS 7
2 BURNER'S PRIMARY AIR FANS 2
1 PREHEATER IDF. 1
2 COLLECTOR IDF 2

GENERAL TRANSPORTATION:
2 WEIGHT FEEDER 6
1,2 FEEDER PLATES 3
1,2 CONVEYOR BELT 6
1,2 FULLER PUMP 2
1 HAULING CHAIN 1
1,2 FULLER COMPRESSOR 2
1,2 BUCKET ELEVATOR 8
1 BUCKET CARRIER 1
1 PLATE CARRIER 1

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PRIORITY PACKING PALLETIZING QUANTITY

2 ROTARY PACKER TRANSMISSION 2
1 MOTOR PULLEYS 4

SERVICES:
3 CENTRIFUGAL PUMP (HORIZONTAL AND VERTICAL) 4
2 THERMICAL OIL PUMP 2
3 FUEL OIL PUMP 4
3 DEEP WELL PUMP 3
3 AIR COMPRESSOR 8

VARIOUS EQUIPMENT:
2 LUBRICATION PUMP 8
2 HYDRAULIC PUMP 4
2 LUBRICATION COMPRESSOR 1
2 TURBO VENTILATORS 10
3 DUST COLLECTOR VENTILATORS 15
3 PRESSURIZER VENTILATORS 10

APPROXIMATE EQUIPMENT QUANTITY 141

THIS EQUIPMENT AND ITS PRIORITY ARE AN EXAMPLE OF RECOMMENDED EQUIPMENT

TO BE TAKEN INTO ACCOUNT IN A PREDICTIVE MAINTENANCE SYSTEM FOR A SINGLE
PRODUCTION LINE. THIS LIST SHOULD BE MODIFIED ACCORDING TO THE PRODUCTION
LINE NEEDS AND THE PLANT'S SPECIFIC CRITERIA.

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CHAPTER 5
Technical information by
equipment type.
5.1 Introduction
One of the most important aspects in the
Preventive-Predictive Maintenance System
is the available information about the
equipment parts. The more complete
information about equipment components
the easier will be the configuration process
of the spectral alarm bands, as it will be
seen in Chapter 6. In addition, the spectral
analysis will be improved considerably with
complete data information.
In this chapter, necessary forms will be
presented to store the minimum required
information of various equipment
components. Due to the great diversity of
equipment types, the major kinds of the
most typical equipment in industry will be
presented.
However, the user can elaborate a similar
format for the types of equipment that are
not included in this chapter.
5.2 Comments about the formats
The formats that are included in this
chapter have in the right upper corner
general information about the equipment.
The first three spaces were designed with
appropriate lengths to include the
appropriate information into the CSI Master
Trend software. We are going to comment
on different segments of this format.
EQUIPMENT IDENTIFICATION
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The name of the equipment should be
registered in alphabetical order with the
maximum of 10 characters. CSI Master
Trend will locate the equipment thanks to
the assigned identification. The same
identification will appear in the data
collector, as well as in all the system's wave
spectra and shapes reports. Consequently,
it is very important to identify them
according to plant's usage.
SECTION
In this space of 28 characters, one should
include the name of the section to which
the equipment belongs. For example:
Equipment: North Induced Draft Ventilator
Identification: 5205-84
Section: Cement Kiln 2
TYPE OF EQUIPMENT
The specific work type performed by the
equipment should be selected. This
information will determine the way the
information is registered. For example,
when the velocity is constant and the load
varies, it is recommended to record the
load at the time of reading.
The Master Trend software requires this
information when the equipment is included
into the system.
MONITORING FREQUENCY
The schedule for the equipment's vibration
reading needs to be determined. This
decision depends on the equipment's
priority in the process. The usual time
sequence for the industrial equipment
reading is one month (monthly).
The rest of the spaces is reserved for the
specific data of each equipment part.
SCHEMATIC DIAGRAM
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In addition, a schematic diagram of the

equipment is included to show the place
where the measurements should be taken.
The equipment's nomenclature of the
measuring points is shown in each diagram.
The letters H, V and A will show the position
of the sensor; which are respectively
Horizontal, Vertical and Axial.

In case of the induction motors, E1H and

E2H points will be added to record the low
and high frequency spectra respectively in
order to be able to counteract possible
electric problems. The configuration of
these measurement points will be explained
in Chapter 6, Table III, pages 6-18.

In case of the gear boxes, it will be

necessary to define additional monitoring
points to record the gearing frequency. In
the schematic diagrams, these
measurement points should be identified.
The configuration of these points is shown
on Table III, page 6-17.

ANALYSIS PARAMETERS

On the back of each form, the definition of

the analysis parameters of the spectral
bandwidth is included, as well as the alarm
level that each band will have.

In some cases, the analysis parameters will

be similar when they are in the same
equipment subdivision, and it will be only
necessary to refer to the equipment that
has its parameters established in order to
use them in the information recording.

In order to fill in correctly this table, it will

be necessary to use the information from
tables II and III, which are included in
chapter 6.

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SCHEMATIC EQUIPMENT DIAGRAM

MEASUREMENT POINTS
EQUIPMENT DESCRIPTION:

4H 3H
4V 3V IDENTIFICATION:
4A 3A

F SECTION:
A
N TYPE OF EQUIPMENT:
CONSTANT VELOCITY, CONSTANT LOAD
CONSTANT VELOCITY, VARIABLE LOAD
VARIABLE VELOCITY, CONSTANT LOAD
MOTOR VARIABLE VELOCITY, VARIABLE LOAD

MONITORING FREQUENCY:
WEEKLY MONTHLY OTHER:
1H, 1V 2H, 2V FORTNIGHTLY BIMESTRIAL
1A, E1H 2A, E2H
ANALYST: _________________________________
E1H and E2H will be used to detect electrical frequencies.
SPECIFIC FAN INFORMATION

MOTOR INFORMATION:
Brand:___________________________
Serial number: _______________________
HP: ________________________________
Plate current: ________________________
Voltage: ____________________________
Brand: _____________________________
Serial no: _________________________
CFM flow: _______________________
Operation temperature: _____________
Number of blades: ____________________
Ventilator type:

Motor Type: Forced type Induced type Closed circuit

Induction: Synchronous:
RPM reference: __________
No. poles: ______
No. rotor rods (bars) _______
No. stator grooves: ______
No. commutator grooves
Direct current:
Diameter of the motor's pulley (Dm): ______
Diameter of the ventilator's pulley (Dv): ____
Groove number and the section type: ______
Distance between axle centers: ________

Spinning velocity:
Type of support:
1. Free side 2. Loading side
RPM fan = RPM motor X (Dm/Dv)= _____

Ball bearing Ball bearing Type of support:

Brand and no.: _______ Brand and no.: _______ 1. Free side 2. Loading side

Roller bearing Roller bearing Ball bearing Ball bearing

Brand and no.: _______ Brand and no.: _______ Brand and no.: _______ Brand and no.: _______

Journal bearing Journal bearing Roller bearing Roller bearing

Brand and no.: _______ Brand and no.: _______
The spectral bandwidth and its alarm levels are on the
backside of this form. Journal bearing Journal bearing

Note: If a motor has a cooling ventilator it will be The spectral bandwidth and its alarm levels are on the
considered as additional equipment. backside of this form.

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SCHEMATIC EQUIPMENT DIAGRAM EQUIPMENT DESCRIPTION:

MEASUREMENT POINTS
3H 4H IDENTIFICATION:
3V 4V F
3A 4A
A SECTION:
N

TYPE OF EQUIPMENT:
CONSTANT VELOCITY, CONSTANT LOAD
CONSTANT VELOCITY, VARIABLE LOAD
VARIABLE VELOCITY, CONSTANT LOAD
MOTOR
VARIABLE VELOCITY, VARIABLE LOAD

MONITORING FREQUENCY:
2H, 2V 1H, 1V
2A, E2H 1A, E1H WEEKLY MONTHLY OTHER:
FORTNIGHTLY BIMESTRIAL
E1H and E2H will be used to detect electrical frequencies. ANALYST: _________________________________

SPECIFIC FAN INFORMATION

MOTOR INFORMATION: Brand: _____________________________

Brand:___________________________ Serial no: _________________________
Serial number: _______________________ CFM flow: _______________________
HP: ________________________________ Operation temperature: _____________
Plate current: ________________________ Number of blades: ____________________
Voltage: ____________________________
Ventilator type:
Motor Type: Forced type Induced type Closed circuit
Induction: Synchronous: Direct current:
RPM reference: __________
No. poles: ______
Diameter of the motor's pulley (Dm): ______
No. rotor rods (bars) _______ Diameter of the ventilator's pulley (Dv): ____
No. stator grooves: ______ Groove number and the section type: ______
No. commutator grooves Distance between axle centers: ________

Type of support: Spinning velocity:

1. Free side 2. Loading side RPM fan = RPM motor X (Dm/Dv)= _____
Ball bearing Ball bearing Type of support:
Brand and no.: _______ Brand and no.: _______ 1. Free side 2. Loading side
Roller bearing Roller bearing Ball bearing Ball bearing
Brand and no.: _______ Brand and no.: _______ Brand and no.: _______ Brand and no.: _______
Journal bearing Journal bearing Roller bearing Roller bearing
Brand and no.: _______ Brand and no.: _______
The spectral bandwidth and its alarm levels are on the
backside of this form. Journal bearing Journal bearing
Note: If a motor has a cooling ventilator it will be The spectral bandwidth and its alarm levels are on the
considered as additional equipment. backside of this form.

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SCHEMATIC EQUIPMENT DIAGRAM

EQUIPMENT DESCRIPTION:
MEASUREMENT POINTS

3H 4H IDENTIFICATION:
3V 4V
3A 4A SECTION:

F TYPE OF EQUIPMENT:
A CONSTANT VELOCITY, CONSTANT LOAD
MOTOR
CONSTANT VELOCITY, VARIABLE LOAD
N
VARIABLE VELOCITY, CONSTANT LOAD
VARIABLE VELOCITY, VARIABLE LOAD

1H 2H MONITORING FREQUENCY:
1V 2V WEEKLY MONTHLY OTHER:
1A 2A FORTNIGHTLY BIMESTRIAL
E1H E2H
ANALYST: _________________________________
E1H and E2H will be used to detect electrical
SPECIFIC FAN INFORMATION

MOTOR INFORMATION: Brand: _____________________________

Brand:___________________________ Serial no: _________________________
Serial number: _______________________ CFM flow: _______________________
HP: ________________________________ Operation temperature: _____________
Plate current: ________________________ Number of blades: ____________________
Voltage: ____________________________ Ventilator type:
Motor Type: Forced type Induced type Closed circuit
Induction: Synchronous: Direct current:
RPM reference: __________
Diameter of the motor's pulley (Dm): ______
No. poles: ______
No. rotor rods (bars) _______ Diameter of the ventilator's pulley (Dv): ____
No. stator grooves: ______ Groove number and the section type: ______
No. commutator grooves Distance between axle centers: ________

Type of support: Spinning velocity:

1. Free side 2. Loading side RPM fan = RPM motor X (Dm/Dv)= _____
Ball bearing Ball bearing Type of support:
Brand and no.: _______ Brand and no.: _______ 1. Free side 2. Loading side

Roller bearing Roller bearing Ball bearing Ball bearing

Brand and no.: _______ Brand and no.: _______ Brand and no.: _______ Brand and no.: _______

Journal bearing Journal bearing Roller bearing Roller bearing

Brand and no.: _______ Brand and no.: _______
The spectral bandwidth and its alarm levels are on the
backside of this form. Journal bearing Journal bearing

Note: If a motor has a cooling ventilator it will be The spectral bandwidth and its alarm levels are on the
considered as additional equipment. backside of this form.

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SCHEMATIC EQUIPMENT DIAGRAM EQUIPMENT DESCRIPTION:

MEASUREMENT POINTS
3H 4H IDENTIFICATION:
3V 4V
3A 4A F SECTION:
A
N
MOTOR TYPE OF EQUIPMENT:
CONSTANT VELOCITY, CONSTANT LOAD
1H, 1V 2H, 2V
1A, E1H 2A, E2H CONSTANT VELOCITY, VARIABLE LOAD
VARIABLE VELOCITY, CONSTANT LOAD
VARIABLE VELOCITY, VARIABLE LOAD

MONITORING FREQUENCY:
E1H and E2H will be used to detect electrical frequencies.
WEEKLY MONTHLY OTHER:
FORTNIGHTLY BIMESTRIAL

ANALYST: _________________________________

MOTOR INFORMATION: SPECIFIC FAN INFORMATION

Brand:___________________________
Serial number: _______________________
HP: ________________________________
Plate current: ________________________
Voltage: ____________________________
Motor Type:
Induction: Synchronous:
RPM reference: __________
No. poles: ______
No. rotor rods (bars) _______
No. stator grooves: ______
No. commutator grooves
Type of support:
1. Free side
Brand: _____________________________
Serial no: _________________________
CFM flow: _______________________
Operation temperature: _____________
Number of blades: ____________________
Direct current: Ventilator type:
Forced type Induced type Closed circuit
Diameter of the motor's pulley (Dm): ______
Diameter of the ventilator's pulley (Dv): ____
Groove number and the section type: ______
Distance between axle centers: ________
2. Loading side

Ball bearing Ball bearing Spinning velocity:

Brand and no.: _______ Brand and no.: _______ RPM fan = RPM motor X (Dm/Dv)= _____

Roller bearing Roller bearing Type of support:

Brand and no.: _______ Brand and no.: _______ 1. Free side 2. Loading side

Journal bearing Journal bearing Ball bearing Ball bearing

Brand and no.: _______ Brand and no.: _______
The spectral bandwidth and its alarm levels are on the
backside of this form. Roller bearing Roller bearing
Brand and no.: _______ Brand and no.: _______
Note: If a motor has a cooling ventilator it will be
considered as additional equipment. Journal bearing Journal bearing

The spectral bandwidth and its alarm levels are on

the backside of this form.

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SCHEMATIC EQUIPMENT DIAGRAM

MEASUREMENT POINTS EQUIPMENT DESCRIPTION:

IDENTIFICATION:
FAN

SECTION:
MOTOR

1H 2H TYPE OF EQUIPMENT:
1V 2V CONSTANT VELOCITY, CONSTANT LOAD
1A 2A
E1H E2H CONSTANT VELOCITY, VARIABLE LOAD
VARIABLE VELOCITY, CONSTANT LOAD
VARIABLE VELOCITY, VARIABLE LOAD

MONITORING FREQUENCY:
WEEKLY MONTHLY OTHER:
FORTNIGHTLY BIMESTRIAL
E1H and E2H will be used to detect electrical frequencies.
ANALYST: _________________________________

SPECIFIC FAN INFORMATION

MOTOR INFORMATION: Brand: _____________________________

Brand:___________________________
Serial number: _______________________
HP: ________________________________
Plate current: ________________________
Voltage: ____________________________
Motor Type:
Induction: Synchronous:
RPM reference: __________
No. poles: ______
No. rotor rods (bars) _______
No. stator grooves: ______
No. commutator grooves
Serial no: _________________________
CFM flow: _______________________
Operation temperature: _____________
Number of blades: ____________________
Ventilator type:
Forced type Induced type Closed circuit
Direct current:
Diameter of the motor's pulley (Dm): ______
Diameter of the ventilator's pulley (Dv): ____
Groove number and the section type: ______
Distance between axle centers: ________

Type of support: Spinning velocity:

1. Free side 2. Loading side RPM fan = RPM motor X (Dm/Dv)= _____
Ball bearing Ball bearing
Type of support:
Brand and no.: _______ Brand and no.: _______
1. Free side 2. Loading side
Roller bearing Roller bearing
Ball bearing Ball bearing
Brand and no.: _______ Brand and no.: _______
Brand and no.: _______ Brand and no.: _______
Journal bearing Journal bearing
Roller bearing Roller bearing
Brand and no.: _______ Brand and no.: _______
The spectral bandwidth and its alarm levels are on the
backside of this form.
Journal bearing Journal bearing
Note: If a motor has a cooling ventilator it will be
The spectral bandwidth and its alarm levels are on
considered as additional equipment.
the backside of this form.

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SCHEMATIC EQUIPMENT DIAGRAM EQUIPMENT DESCRIPTION:

MEASUREMENT POINTS
IDENTIFICATION:
FAN

SECTION:
MOTOR

TYPE OF EQUIPMENT:
1H 2H
1V 2V CONSTANT VELOCITY, CONSTANT LOAD
1A 2A CONSTANT VELOCITY, VARIABLE LOAD
E1H E2H
VARIABLE VELOCITY, CONSTANT LOAD
VARIABLE VELOCITY, VARIABLE LOAD

MONITORING FREQUENCY:
WEEKLY MONTHLY OTHER:
FORTNIGHTLY BIMESTRIAL
E1H and E2H will be used to detect electrical frequencies.
ANALYST: _________________________________

SPECIFIC FAN INFORMATION

MOTOR INFORMATION:
Brand:___________________________
Serial number: _______________________
HP: ________________________________
Plate current: ________________________
Voltage: ____________________________
Motor Type:
Induction: Synchronous:
RPM reference: __________
No. poles: ______
No. rotor rods (bars) _______
No. stator grooves: ______
No. commutator grooves
Type of support:
1. Free side
Ball bearing
Brand and no.: _______
Roller bearing
Brand and no.: _______
Journal bearing
The spectral bandwidth and its alarm levels are on the
backside of this form.
Note: If a motor has a cooling ventilator it will be
considered as additional equipment.
Brand: _____________________________
Serial no: _________________________
CFM flow: _______________________
Operation temperature: _____________
Number of blades: ____________________
Ventilator type:
Forced type Induced type Closed circuit
Diameter of the motor's pulley (Dm): ______
Direct current:
Diameter of the ventilator's pulley (Dv): ____
Groove number and the section type: ______
Distance between axle centers: ________
Spinning velocity:
RPM fan = RPM motor X (Dm/Dv)= _____
2. Loading side Type of support:
1. Free side 2. Loading side
Ball bearing
Brand and no.: _______ Ball bearing Ball bearing
Brand and no.: _______ Brand and no.: _______
Roller bearing
Brand and no.: _______ Roller bearing Roller bearing
Brand and no.: _______ Brand and no.: _______
Journal bearing
Journal bearing Journal bearing
The spectral bandwidth and its alarm levels are on
the backside of this form.

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SCHEMATIC EQUIPMENT DIAGRAM THAT

EQUIPMENT DESCRIPTION:
SHOWS MEASUREMENT POINTS

IDENTIFICATION:

SECTION:
IM
PU
MOTOR LS TYPE OF EQUIPMENT:
E
TU CONSTANT VELOCITY, CONSTANT LOAD
R CONSTANT VELOCITY, VARIABLE LOAD
BI
NE VARIABLE VELOCITY, CONSTANT LOAD
VARIABLE VELOCITY, VARIABLE LOAD
1H 2H
1V 2V MONITORING FREQUENCY:
1A 2A WEEKLY MONTHLY OTHER:
E1H E2H FORTNIGHTLY BIMESTRIAL

ANALYST: _________________________________

E1H and E2H will be used to detect electrical frequencies.

MOTOR INFORMATION: SPECIFIC PUMP INFORMATION

Brand:___________________________
Serial number: _______________________
HP: ________________________________
Plate current: ________________________
Voltage: ____________________________
Motor Type:
Induction: Synchronous:
RPM reference: __________
No. poles: ______
No. rotor rods (bars) _______
No. stator grooves: ______
No. commutator grooves
Brand: _____________________________
Serial no.:________________________
Flow in gallons/min.:_________________
Operating temperature__________
Number of blades :___________
Pump type:
Direct current: Centrifugal Hydraulic Positive displacement
Coupling type: __________
Coupling brand: __________________________

Type of support:
1. Free side 2. Loading side

Ball bearing Ball bearing

Brand and no.: _______ Brand and no.: _______

Roller bearing Roller bearing

Brand and no.: _______ Brand and no.: _______

Journal bearing Journal bearing

The spectral bandwidth and its alarm levels are on the

backside of this form.

Note: If a motor has a cooling ventilator it will be

considered as additional equipment

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Code . . .

SCHEMATIC EQUIPMENT DIAGRAM

MEASUREMENT POINTS
EQUIPMENT DESCRIPTION:
1A

IDENTIFICATION:
1P 1F, E1F
M
O SECTION:
T
O
2A
2P
R TYPE OF EQUIPMENT:
2F, E2F
CONSTANT VELOCITY, CONSTANT LOAD
3A 3F CONSTANT VELOCITY, VARIABLE LOAD
3P VARIABLE VELOCITY, CONSTANT LOAD
P VARIABLE VELOCITY, VARIABLE LOAD
F = fluid direction
P = perpendicular with the U
MONITORING FREQUENCY:
flow M WEEKLY MONTHLY OTHER:
P FORTNIGHTLY BIMESTRIAL

ANALYST: _________________________________
E1H and E2H will be used to detect electrical frequencies.

MOTOR INFORMATION: SPECIFIC PUMP INFORMATION

Brand:___________________________
Serial number: _______________________
HP: ________________________________
Plate current: ________________________
Voltage: ____________________________
Motor Type:
Induction: Synchronous:
RPM reference: __________
No. poles: ______
No. rotor rods (bars) _______
No. stator grooves: ______
No. commutator grooves
Brand: _____________________________
Serial no.:________________________
Flow in gallons/min.:_________________
Operating temperature__________
Number of blades :___________
Pump type:
Direct current: Centrifugal Hydraulic Positive displacement
Coupling type: __________
Coupling brand: ____________________________

Type of support:
1. Free side 2. Loading side Type of support:
1. Free side 2. Loading side
Ball bearing Ball bearing
Brand and no.: _______ Brand and no.: _______ Ball bearing Ball bearing
Brand and no.: _______ Brand and no.: _______
Roller bearing Roller bearing
Brand and no.: _______ Brand and no.: _______ Roller bearing Roller bearing
Brand and no.: _______ Brand and no.: _______
Journal bearing Journal bearing
Journal bearing Journal bearing
The spectral bandwidth and its alarm levels are on the
backside of this form. The spectral bandwidth and its alarm levels are on
the backside of this form.
Note: If a motor has a cooling ventilator it will be
considered as additional equipment

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SCHEMATIC EQUIPMENT DIAGRAM

MEASUREMENT POINTS
3H 4H
3V 4V EQUIPMENT DESCRIPTION:
3A 4A

IDENTIFICATION:

SCREW SECTION:
MOTOR COMPRESSOR

TYPE OF EQUIPMENT:
5H 6H CONSTANT VELOCITY, CONSTANT LOAD
1H,1V 2H, 2V 5V 6V
1A, E1H 2A, E2H CONSTANT VELOCITY, VARIABLE LOAD
5A 6A
VARIABLE VELOCITY, CONSTANT LOAD
VARIABLE VELOCITY, VARIABLE LOAD
E1H and E2H will be used to detect electrical frequencies..
MONITORING FREQUENCY:
WEEKLY MONTHLY OTHER:
FORTNIGHTLY BIMESTRIAL

MOTOR INFORMATION: ANALYST: _________________________________

Brand:___________________________
Serial number: _______________________
HP: ________________________________
Plate current: ________________________
Voltage: ____________________________
Motor Type:
Induction: Synchronous:
RPM reference: __________
No. poles: ______
No. rotor rods (bars) _______
No. stator grooves: ______
No. commutator grooves
SPECIFIC COMPRESSOR INFORMATION
Brand: ___________Serial no.: _______________
Maximum working pressure: _________________
Operational flow in CFM: ___________________
Direct current: Coupling brand: ___________________________
No. of parts: ______________________________
No. of pinion entrance teeth (Np): _____________
No. of high velocity globe axles (La): __________
No. of low velocity globe axles (Lb): ___________
RPM high axle = RPM motor x (Np/Nc)
RPM low axle = RPM high axle X (La/Lb)

Type of support:
1. Free side 2. Loading side Type of high velocity axle support:
3. Loading side 4. Free side
Ball bearing Ball bearing ball bearing ball bearing
Brand and no.: _______ Brand and no.: _______ roller bearing roller bearing
pillow block pillow block
Roller bearing Roller bearing
Brand and no.: _______ Brand and no.: _______ brand and no.: _____________

Journal bearing Journal bearing

Type of low velocity axle support:

The spectral bandwidth and its alarm levels are on the
5. Loading side 6. Free side
backside of this form.
ball bearing ball bearing
roller bearing roller bearing
Note: If a motor has a cooling ventilator it will be pillow block pillow block
considered as additional equipment
brand and no.: _____________

The spectral band width and its alarm levels are on the
backside of this form
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Code . . .

SCHEMATIC EQUIPMENT DIAGRAM

EQUIPMENT DESCRIPTION:
MEASUREMENT POINTS
4H 3H
4V 3V IDENTIFICATION:
4A 3A
SECTION:

Crusher TYPE OF EQUIPMENT:

CONSTANT VELOCITY, CONSTANT LOAD
CONSTANT VELOCITY, VARIABLE LOAD
VARIABLE VELOCITY, CONSTANT LOAD
MOTOR
VARIABLE VELOCITY, VARIABLE LOAD

1H, 1V 2H, 2V MONITORING FREQUENCY:

1A, E1H 2A, E2H WEEKLY MONTHLY OTHER:
FORTNIGHTLY BIMESTRIAL
E1H and E2H will be used to detect electrical frequencies.
ANALYST: _________________________________

SPECIFIC CRUSHER INFORMATION

MOTOR INFORMATION:
Brand:___________________________
Serial number: _______________________
HP: ________________________________
Plate current: ________________________
Voltage: ____________________________
Motor Type:
Induction: Synchronous:
RPM reference: __________
No. poles: ______
No. rotor rods (bars) _______
No. stator grooves: ______
No. commutator grooves
Type of support:
1. Free side
Ball bearing
Brand and no.: _______
Roller bearing
Brand and no.: _______
Journal bearing
The spectral bandwidth and its alarm levels are on the
backside of this form.
Note: If a motor has a cooling ventilator it will be
considered as additional equipment
Brand: _____________________________
Serial no.: __________________________
Grinding material: ___________________
Operational temperature: ______________
Number of hammers: _________________
Diameter of the motor's pulley (Dm):_____
Direct current: Diameter of the mill's pulley (Dt): _______
No. grooves and section type: ________
Distance between axle centers: _________
Spinning velocity:
RPM crusher = RPM motor x (Dm/Dt)= __________
Type of support:
2. Loading side
1. Free side 2. Loading side
Ball bearing
Ball bearing Ball bearing
Brand and no.: _______
Brand and no.: _______ Brand and no.: _______
Roller bearing
Roller bearing Roller bearing
Brand and no.: _______
Brand and no.: _______ Brand and no.: _______
Journal bearing
Journal bearing Journal bearing
The spectral band width and its alarm levels are on the
backside of this form.

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Code . . .

SCHEMATIC EQUIPMENT DIAGRAM

EQUIPMENT DESCRIPTION:
MEASUREMENT POINTS

IDENTIFICATION:

1H 2H 3H SECTION:
1V 2V 3V
1A 2A 3A
E1H E2H
TYPE OF EQUIPMENT:
CONE
TRITURATOR CONSTANT VELOCITY, CONSTANT LOAD
MOTOR CONSTANT VELOCITY, VARIABLE LOAD
VARIABLE VELOCITY, CONSTANT LOAD
VARIABLE VELOCITY, VARIABLE LOAD

MONITORING FREQUENCY:
WEEKLY MONTHLY OTHER:
FORTNIGHTLY BIMESTRIAL
E1H and E2H will be used to detect electrical frequencies.
ANALYST: _________________________________

MOTOR INFORMATION:
Brand:___________________________
Serial number: _______________________ SPECIFIC TRITURATOR INFORMATION
HP: ________________________________
Plate current: ________________________ Brand: ____________________________
Voltage: ____________________________
Serial no.: _________________________
Grinding material: ______
Motor Type: Operational temperature: ______________
Induction: Synchronous: Direct current:
Number of cones: ____________________
RPM reference: __________
No. poles: ______
No. rotor rods (bars) _______ Coupling type: _______________________
No. stator grooves: ______ Coupling brand: _____________________
No. commutator grooves

Type of support:
Type of support: 1. Free side 2. Loading side
1. Free side 2. Loading side
Ball bearing Ball bearing
Ball bearing Ball bearing Brand and no.: _______ Brand and no.: _______
Brand and no.: _______ Brand and no.: _______
Roller bearing Roller bearing
Roller bearing Roller bearing Brand and no.: _______ Brand and no.: _______
Brand and no.: _______ Brand and no.: _______
Journal bearing Journal bearing
Journal bearing Journal bearing
The spectral bandwidth and its alarm levels are on
The spectral bandwidth and its alarm levels are on the the backside of this form.
backside of this form.

Note: If a motor has a cooling ventilator it will be

considered as additional equipment
.

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Code . . .

SCHEMATIC EQUIPMENT DIAGRAM

MEASUREMENT POINTS
EQUIPMENT DESCRIPTION:

3H IDENTIFICATION:
3V
1H 2H 3A
SECTION:
1V 2V
1A 2A CONE
E1H E2H TRITURATOR
TYPE OF EQUIPMENT:
CONSTANT VELOCITY, CONSTANT LOAD
MOTOR CONSTANT VELOCITY, VARIABLE LOAD
VARIABLE VELOCITY, CONSTANT LOAD
VARIABLE VELOCITY, VARIABLE LOAD

E1H and E2H will be used to detect electrical frequencies..

MONITORING FREQUENCY:
WEEKLY MONTHLY OTHER:
FORTNIGHTLY BIMESTRIAL

ANALYST: _________________________________

MOTOR INFORMATION:
Brand:___________________________
Serial number: _______________________
HP: ________________________________
Plate current: ________________________
Voltage: ____________________________
Motor Type:
Induction: Synchronous:
RPM reference: __________
No. poles: ______
No. rotor rods (bars) _______
No. stator grooves: ______
No. commutator grooves
Type of support:
1. Free side
SPECIFIC TRITURATOR INFORMATION
Brand: ____________________________
Serial no.: _________________________
Direct current:
Grinding material: ______
Operational temperature: ______________
Number of cones: ____________________
Diameter of the motor's pulley (Dm): ____
Diameter of the mill's pulley (Dt): _______
Number of grooves and the section type: ______
Distance between axle centers: __________
2. Loading side
Spinning speed:

Ball bearing Ball bearing RPM mill= RPM motor x (Dm/Dt)= __________
Brand and no.: _______ Brand and no.: _______

Roller bearing Roller bearing Type of support:

Brand and no.: _______ Brand and no.: _______ 1. Free side 2. Loading side

Journal bearing Journal bearing Ball bearing Ball bearing

Brand and no.: _______ Brand and no.: _______
The spectral bandwidth and its alarm levels are on the
backside of this form. Roller bearing Roller bearing
Brand and no.: _______ Brand and no.: _______
Note: If a motor has a cooling ventilator it will be
considered as additional equipment Journal bearing Journal bearing

The spectral bandwidth and its alarm levels are on the

backside of this form.

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Code . . .

SCHEMATIC EQUIPMENT DIAGRAM EQUIPMENT DESCRIPTION:

MEASUREMENT POINTS
9H 10H IDENTIFICATION:
8H,8V,8A,G8H 9V 10V
9A 10A SECTION:
7H,7V,7A
N4
5H,5V,5A N2 N3 TRANSPORTER'S
PULLEY TYPE OF EQUIPMENT:
6H,6V,6A,G6H CONSTANT VELOCITY, CONSTANT LOAD
MOTOR N1
CONSTANT VELOCITY, VARIABLE LOAD
REDUCER VARIABLE VELOCITY, CONSTANT LOAD
VARIABLE VELOCITY, VARIABLE LOAD

1H 2H 3H 4H MONITORING FREQUENCY:
1V 2V 3V 4V WEEKLY MONTHLY OTHER:
1A 2A 3A 4A FORTNIGHTLY BIMESTRIAL
E1H E2H G3H
ANALYST: _________________________________
E1H and E2H will be used to detect electrical frequencies.
SPECIAL REDUCER INFORMATION:
Brand: ____________________________
Serial No.: _________________________
MOTOR INFORMATION: Number or reduction steps:
Brand:___________________________
Serial number: _______________________ Spinning frequency:
HP: ________________________________ RPMgearN1 = RPM motor (reference) = _________
Plate current: ________________________ RPMgearN2/N3 = RPM motor X (N1/N2) = ______
Voltage: ____________________________ RPMgearN4 = RPMgearN2/N3 X (N3/N4) = _____
Motor Type: Type of support:
Induction: Synchronous: Direct current: Supports 3 and 4 Supports 5 and 6 Supports 7 and 8
RPM reference: __________ ball bearing ball bearing ball bearing
No. poles: ______ roller bearing roller bearing roller bearing
No. rotor rods (bars) _______ Journal bearing Journal bearing.: _____
No. stator grooves: ______
No. commutator grooves Special checking frequency:

Type of support: The points G3H, G6H and G8H are used to obtain spectra that
1. Free side 2. Loading side include the gearing frequency and their maximum frequency
should not be less than:
FMAXG3H = 3 X N1 X RPMMOTOR = __________ X RPMMOTOR
Ball bearing Ball bearing FMAXG6H = 3 X N3 X RPMGEARN/2N3 = _________ X RPMGEARN2/N3
Brand and no.: _______ Brand and no.: _______ FMAXG8H = 3 X N4 X RPMGEARN4 = ___________ X RPMGEARN4

Roller bearing Roller bearing SPECIAL PULLEY INFORMATION:

Brand and no.: _______ Brand and no.: _______

Journal bearing Journal bearing RPM pulley = RPM gearN4 = _____

The spectral bandwidth and its alarm levels are on the 9. Free side 10. Loading side
backside of this form. ball bearing ball bearing
roller bearing roller bearing
Note: If a motor has a cooling ventilator it will be flat strengthening flat strengthening
considered as additional equipment brand and no.: _________ brand and no.: _____

The spectral bandwidth and its alarm levels are on the The spectral bandwidth and its alarm levels are on
backside of this form the backside of this form.

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Code . . .

SCHEMATIC EQUIPMENT DIAGRAM EQUIPMENT DESCRIPTION:

MEASUREMENT POINTS
IDENTIFICATION:
9H 10H
8H,8V,8A,G8H 9V 10V
9A 10A SECTION:
7H,7V,7A
N4
5H,5V,5A N2 N3
THREAD TYPE OF EQUIPMENT:
CONSTANT VELOCITY, CONSTANT LOAD
6H,6V,6A,G6H
MOTOR N1 CONSTANT VELOCITY, VARIABLE LOAD
REDUCTOR
VARIABLE VELOCITY, CONSTANT LOAD
1H 2H
1V 2V VARIABLE VELOCITY, VARIABLE LOAD
3H 4H
1A 2A 3V 4V
E1H E2H 3A 4A MONITORING FREQUENCY:
G3H WEEKLY MONTHLY OTHER:
FORTNIGHTLY BIMESTRIAL
E1H and E2H will be used to detect electrical frequencies.

ANALYST: _________________________________

SPECIAL REDUCER INFORMATION:

MOTOR INFORMATION: Brand: ____________________________
Brand:___________________________ Serial No.: _________________________
Serial number: _______________________ Coupling type on the entrance side________
HP: ________________________________ Coupling type on the exit side: ________
Plate current: ________________________
Voltage: ____________________________ Number or reduction steps:

Motor Type: Spinning frequency:

Induction: Synchronous: Direct current: RPMgearN1 = RPM motor (reference) = _________
RPM reference: __________ RPMgearN2/N3 = RPM motor X (N1/N2) = ______
No. poles: ______ RPMgearN4 = RPMgearN2/N3 X (N3/N4) = _____
No. rotor rods (bars) _______
No. stator grooves: ______
No. commutator grooves Type of support:
Supports 3 and 4 Supports 5 and 6 Supports 7 and 8
ball bearing ball bearing ball bearing
Type of support: roller bearing roller bearing roller bearing
1. Free side 2. Loading side Journal bearing Journal bearing: Journal bearing

Ball bearing Ball bearing Special checking frequency:

Brand and no.: _______ Brand and no.: _______ The points G3H, G6H and G8H are used to obtain spectra
that include the gearing frequency and their maximum
Roller bearing Roller bearing frequency should not be less than:
Brand and no.: _______ Brand and no.: _______ FMAXG3H = 3 X N1 X RPMMOTOR = __________ X
RPMMOTOR
Journal bearing Journal bearing
FMAXG6H = 3 X N3 X RPMGEARN/2N3 = _________ X
The spectral bandwidth and its alarm levels are on the RPMGEARN2/N3
backside of this form. FMAXG8H = 3 X N4 X RPMGEARN4 = ___________ X
RPMGEARN4
Note: If a motor has a cooling ventilator it will be SPECIAL TREAD INFORMATION:
considered as additional equipment RPM pulley = RPMgearN4 = _____
9. Free side 10. Loading side
The spectral bandwidth and its alarm levels are on the Ball bearing Ball bearing
backside of this form Roller bearing Roller bearing
Journal bearing Journal bearing
Brand and no.: _______ Brand and no.: _______

The spectral bandwidth and its alarm levels are on the backside
of this form

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Code . . .

EQUIPMENT DESCRIPTION:
SCHEMATIC EQUIPMENT DIAGRAM
MEASUREMENT POINTS
IDENTIFICATION:
9H 10H
8H,8V,8A,G8H 9V 10V SECTION:
9A 10A
7H,7V,7A
N4 TYPE OF EQUIPMENT:
5H,5V,5A N2 N3 SPROCKET CONSTANT VELOCITY, CONSTANT LOAD
6H,6V,6A,G6H CONSTANT VELOCITY, VARIABLE LOAD
MOTOR N1
VARIABLE VELOCITY, CONSTANT LOAD
REDUCER VARIABLE VELOCITY, VARIABLE LOAD

MONITORING FREQUENCY:
1H 2H 3H 4H WEEKLY MONTHLY OTHER:
1V 2V 3V 4V FORTNIGHTLY BIMESTRIAL
1A 2A 3A 4A
E1H E2H G3H ANALYST: _________________________________

E1H and E2H will be used to detect electrical frequencies. SPECIAL REDUCER INFORMATION:
Brand: ____________________________
Serial No.: _________________________
Coupling type on the entrance side: _____
Coupling type on the exit side: ________
MOTOR INFORMATION:
Number or reduction steps:___________________
Brand:___________________________
Serial number: _______________________ Spinning frequency:
HP: ________________________________ RPMgearN1 = RPM motor (reference) = _________
Plate current: ________________________ RPMgearN2/N3 = RPM motor X (N1/N2) = _______
Voltage: ____________________________ RPMgearN4 = RPMgearN2/N3 X (N3/N4) = _____
Type of support:
Motor Type:
Supports 3 and 4 Supports 5 and 6 Supports 7 and 8
Induction: Synchronous: Direct current:
ball bearing ball bearing ball bearing
RPM reference: __________
roller bearing roller bearing roller bearing
No. poles: ______
Journal bearing Journal bearing: Journal bearing
No. rotor rods (bars) _______
No. stator grooves: ______
No. commutator grooves
Special checking frequency:
The points G3H, G6H and G8H are used to obtain spectra that
include the gearing frequency and their maximum frequency
should
Type of support: not be less than:
1. Free side 2. Loading side FMAXG3H = 3 X N1 X RPMMOTOR = __________ X RPMMOTOR
FMAXG6H = 3 X N3 X RPMGEARN/2N3 = _________ X RPMGEARN2/N3
Ball bearing Ball bearing FMAXG8H = 3 X N4 X RPMGEARN4 = ___________ X RPMGEARN4
Brand and no.: _______ Brand and no.: _______

Roller bearing Roller bearing

SPECIAL SPROCKET INFORMATION:
Brand and no.: _______ Brand and no.: _______ RPM sprocket = RPMgearN4 = _____

Journal bearing Journal bearing SPECIAL TREAD INFORMATION:

RPM pulley = RPMgearN4 = _____
The spectral bandwidth and its alarm levels are on the 9. Free side 10. Loading side
backside of this form. Ball bearing Ball bearing
Roller bearing Roller bearing
Note: If a motor has a cooling ventilator it will be Journal bearing Journal bearing
considered as additional equipment Brand and no.: _______ Brand and no.: _______

The spectral bandwidth and its alarm levels are on the The spectral bandwidth and its alarm levels are on the backside
backside of this form of this form

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Code . . .

.
SCHEMATIC EQUIPMENT DIAGRAM
MEASUREMENT POINTS EQUIPMENT DESCRIPTION:

9H 10H IDENTIFICATION:
8H,8V,8A,G8H 9V 10V
9A 10A
SECTION:
7H,7V,7A
N4
5H,5V,5A N2 N3 DRIVING PINION
TYPE OF EQUIPMENT:
6H,6V,6A,G6H CONSTANT VELOCITY, CONSTANT LOAD
MOTOR N1
CONSTANT VELOCITY, VARIABLE LOAD
VARIABLE VELOCITY, CONSTANT LOAD
REDUCER

VARIABLE VELOCITY, VARIABLE LOAD

1H 2H 3H 4H
1V 2V 3V 4V MONITORING FREQUENCY:
1A 2A 3A 4A WEEKLY MONTHLY OTHER:
E1H E2H G3H FORTNIGHTLY BIMESTRIAL

ANALYST: _________________________________
E1H and E2H will be used to detect electrical frequencies.

SPECIAL REDUCER INFORMATION:

Brand: ____________________________
MOTOR INFORMATION: Serial No.: _________________________
Brand:___________________________ Coupling type on the entrance side: _____
Serial number: _______________________ Coupling type on the exit side: ________
HP: ________________________________ Number or reduction steps:___________________
Plate current: ________________________
Spinning frequency:
Voltage: ____________________________
RPMgearN1 = RPM motor (reference) = _________
RPMgearN2/N3 = RPM motor X (N1/N2) = _______
Motor Type:
RPMgearN4 = RPMgearN2/N3 X (N3/N4) = _____
Induction: Synchronous: Direct current:
RPM reference: __________ Type of support:
No. poles: ______ Supports 3 and 4 Supports 5 and 6 Supports 7 and 8
No. rotor rods (bars) _______ ball bearing ball bearing ball bearing
No. stator grooves: ______ roller bearing roller bearing roller bearing
No. commutator grooves Journal bearing Journal bearing: Journal bearing

Special checking frequency:

Type of support: The points G3H, G6H and G8H are used to obtain spectra that include
1. Free side 2. Loading side the gearing frequency and their maximum frequency should not be
less than:
Ball bearing Ball bearing FMAXG3H = 3 X N1 X RPMMOTOR = __________ X RPMMOTOR
Brand and no.: _______ Brand and no.: _______ FMAXG6H = 3 X N3 X RPMGEARN/2N3 = _________ X RPMGEARN2/N3
FMAXG8H = 3 X N4 X RPMGEARN4 = ___________ X RPMGEARN4
Roller bearing Roller bearing
Brand and no.: _______ Brand and no.: _______
SPECIAL PINION INFORMATION:
Journal bearing Journal bearing RPM pinion = RPMgearN4 = _____
9. Free side 10. Loading side
The spectral bandwidth and its alarm levels are on the Ball bearing Ball bearing
backside of this form. Roller bearing Roller bearing
Journal bearing Journal bearing
Note: If a motor has a cooling ventilator it will be Brand and no.: _______ Brand and no.: _______
considered as additional equipment Number of pinion teeth: __________

The spectral bandwidth and its alarm levels are on the The spectral bandwidth and its alarm levels are on the
backside of this form backside of this form.

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Code . . .

SCHEMATIC EQUIPMENT DIAGRAM EQUIPMENT DESCRIPTION:

MEASUREMENT POINTS
6V 8H 5H
6A
G6V
8V
8A
5V
G5V IDENTIFICATION:

SECTION:
N3= N4= N3=

TYPE OF EQUIPMENT:
CONSTANT VELOCITY, CONSTANT LOAD
CONSTANT VELOCITY, VARIABLE LOAD
VARIABLE VELOCITY, CONSTANT LOAD
N2= N1= N2=
VARIABLE VELOCITY, VARIABLE LOAD
2H,G2H
7V 4V MONITORING FREQUENCY:
1V,G1V
7A
G7V 0A,G0A
4A
G4V WEEKLY MONTHLY OTHER:
COUPLER
FORTNIGHTLY BIMESTRIAL
CIH,CIV,CIA APOYO “C”

COUPLER
ANALYST: _________________________________
MCH,MCV,MCA
C = COUPLING SIDE

MOTOR
SPECIAL REDUCER INFORMATION:
MLH,MLV,MLA
L = FREE SIDE
Brand: ____________________________
Serial No.: _________________________
Coupling type on the entrance side: _____
Coupling type on the exit side: _________
MOTOR INFORMATION:
Brand:___________________________ Spinning frequency:
Serial number: _______________________ RPMgearN2/N3 = RPM motor X (N1/N2) = ________
HP: ________________________________
Plate current: ________________________
RPMgearN4 = RPMgearN2/N3 X (N3/N4) = _______
Voltage: ____________________________
Type of support:
Motor Type:
Supports 3 and 4 Supports 5 and 6 Supports 7 and 8
Induction: Synchronous: Direct current: ball bearing ball bearing ball bearing
RPM reference: __________ roller bearing roller bearing roller bearing
No. poles: ______ Journal bearing Journal bearing: Journal bearing
No. rotor rods (bars) _______
No. stator grooves: ______
No. commutator grooves Coupling side entrance Pinion side entrance

9. Free side 10. Loading side

Type of support: Ball bearing Ball bearing
1. Free side 2. Loading side Roller bearing Roller bearing
Journal bearing Journal bearing
Ball bearing Ball bearing Brand and no.: _______ Brand and no.: _______
Brand and no.: _______ Brand and no.: _______

Roller bearing Roller bearing Special checking frequency:

Brand and no.: _______ Brand and no.: _______ The points G3H, G6H and G8H are used to obtain spectra that
include the gearing frequency and their maximum frequency
Journal bearing Journal bearing should not be less than:
FMAXG0A/G1V = 3 X N1 X RPMMOTOR = _________ X RPMMOTOR
The spectral bandwidth and its alarm levels are on the FMAXG4V/G7V = 3 X N2 X RPMGEARN2/N3 = _________ X
backside of this form. RPMGEARN2/N3
FMAXG5V/G6V = 3 X N3 X RPMGEARN2/N3 = ________ X
Note: If a motor has a cooling ventilator it will be RPMGEARN2/N3
considered as additional equipment

The spectral bandwidth and its alarm levels are on the

backside of this form

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Code . . .

SCHEMATIC EQUIPMENT DIAGRAM THAT

SHOWS MEASUREMENT POINTS
EQUIPMENT DESCRIPTION:
1H 2H REDUCING MAAG
1V 2V 4H
1A 2A 4G N4 N3 IDENTIFICATION:
E1H E2H 3H,3V
3A,3G N1 SECTION:
X X X X
MOTOR X X N2
X X
TYPE OF EQUIPMENT:
CONSTANT VELOCITY, CONSTANT LOAD
CONSTANT VELOCITY, VARIABLE LOAD
VARIABLE VELOCITY, CONSTANT LOAD
VARIABLE VELOCITY, VARIABLE LOAD
E1H and E2H will be used to detect electrical frequencies.
MONITORING FREQUENCY:
WEEKLY MONTHLY OTHER:
FORTNIGHTLY BIMESTRIAL

ANALYST: _________________________________

SPECIAL REDUCER INFORMATION:

MOTOR INFORMATION: Brand: ____________________________
Brand:___________________________
Serial number: _______________________
Serial No.: _________________________
HP: ________________________________ Number of reduction steps: _________
Plate current: ________________________
Voltage: ____________________________ Spinning frequency:

Motor Type: RPMgearN1 = RPM motor (reference) = _________

Induction: Synchronous: Direct current:
RPM reference: __________
RPMgearN2/N3 = RPM motor X (N1/N2) = _______
No. poles: ______
No. rotor rods (bars) _______ Type of support:
No. stator grooves: ______
No. commutator grooves Supports N1 Supports N2
ball bearing ball bearing
Type of support: roller bearing roller bearing
1. Free side 2. Loading side Journal bearing Journal bearing

Ball bearing Ball bearing Special checking frequency:

Brand and no.: _______ Brand and no.: _______ The points G3H, G6H and G8H are used to obtain spectra that
include the gearing frequency and their maximum frequency
Roller bearing Roller bearing should not be less than:
Brand and no.: _______ Brand and no.: _______
FMAXG3A = 3 X N1 X RPMMOTOR = _________ X RPMMOTOR
Journal bearing Journal bearing FMAXG4H = 3 X N3 X RPMGEARN2/N3 = ________ X
RPMGEARN2/N3
The spectral bandwidth and its alarm levels are on the
backside of this form. The spectral band width and its alarm levels are on the back
side of this form.
Note: If a motor has a cooling ventilator it will be
considered as additional equipment

The spectral bandwidth and its alarm levels are on the

backside of this form

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OPERATIONS/ MAINTENANCE
VIBRATION MANUAL
CHAPTER 6
General procedure for the
assignation of the narrow band
alarm levels for different types
of equipment.
6.1 Introduction
Even though there is a lot of available
literature on problem diagnosis using the
vibration analysis approach, there is very
little material on the appropriate method to
specify effectively the perimeters of the
spectral band alarms for various types of
equipment.
If these bands are used during the analysis
process, the user can save thousands of
pesos in maintenance expenses and they
can significantly increase the plant's
profitability. First, one has to determine
that equipment has a problem, and second,
one has to diagnose its cause and severity.
The purpose of this chapter is to provide
the user with a technical document which
shows how to specify the alarm levels in
peak velocity and the manner in which to
define the spectral band frequencies in
order to measure the vibrations levels in
general processing equipment and in the
service area.
When these spectral bands and their alarm
levels are appropriately defined for the
specific type of equipment, bearing type
and spinning frequency, valuable
information will be obtained in order to
prevent "false alarms".
This chapter's information is primarily
applied to the preventive maintenance
software which has 6 alarms spectral bands
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as is the case of CSI Master Trend Plus
system.
The main part of the predictive
maintenance system is based on the
appropriate definition of the spectral band
alarm levels that will provide the necessary
information for the potentially serious
problem detection in equipment.
Even if we could obtain the "perfect" alarm
specification value for the total equipment
vibration, very serious potential problems
could arise; these would have an almost
imperceptible effect on the global
vibration. However, these problems can be
observed in the spectrum.
But if the user does not use the spectral
band technique for the alarm levels
specification, it is probable that he will not
detect a significant change in the global
vibration levels, however the equipment
could have a serious problem that was not
detected.
We are suggesting potential problems like
worn out gear, gears in poor condition or an
electric problem.
For example, failure frequency of a bearing
could increase by a factor of 4, from 0.03 to
0.12 in./sec. and cause an insignificant
change in the vibration's global value if the
1X and 2X were respectively 35 in./sec. and
0.20 in./sec. (in this case the vibration's
global value would be approximately from
0.4 to 0.42 in./sec.). Consequently, it is
not recommended to use only the vibration's
global value.
Consequently, the fundamental objective of
this chapter is to offer a procedure to
specify the correct spectral band alarms for
different equipment configurations. This
procedure is summarized in Table III.
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6.2 Different types of spectral band
alarms
It is important to note that there are two
types of the preventive maintenance
spectral band alarms that most software
salesmen offer: 1) absolute peak, and 2)
power band. The CSI Master Trend software
uses power bands.
The absolute peak systems help the user
specify the maximum permissible amplitude
of each peak within each defined narrow
band. If any of these peaks equals or
exceeds this value, the alarm of this
specific band will be activated.
On the other hand, the power band systems
calculate the total energy within each band
which is created by all the peaks from the
same band.
The total power of each band is calculated
using the same equation that is used for the
global value calculation for the complete
spectrum:
n Second, the analyst will have to define
∑ Fi2
i =1
VG = EQUATION 1
NBF
VG = Vibration Global Value
n = Number of resolution lines
Fi = Spectral line amplitude
NBF = Noise, as of chosen window
= 1.5 Hanning window
For the power band case, note that it is not
necessary that only one individual peak in
the band equals or exceeds the alarm value
to activate it.
For example, if a band that is defined from
0.5 FMAX to FMAX using 400 resolution lines
for the spectrum, the equation 1 will be
used to calculate the line range for the
resolution of 200 to 400, which corresponds
to the area of 0.5 FMAX to FMAX.
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If we define the alarm level of 0.2 in./sec.,
two peaks of 0.175 in./sec. and 0.185
in./sec. will be sufficient to activate the
alarm. Note that none of the two peaks
exceeds the value of 0.2 in./sec.
These power bands will be used in Table III
because they are a good indicator of what
occurs in the spectral band.
6.3 Vibration-Movement, speed and
acceleration parameters
Two important points will be taken into
account before defining the spectral band
alarms.
First, the analyst should know which
frequencies are generated by different parts
of the equipment. For example, ball and
roller bearings, strengthening plates, gears,
electric problems, unbalance, movement,
etc.
which vibration parameters (movement,
speed or acceleration) he will use to detect
in the best possible way the problems that
can be observed in equipment.
Table 1 shows that while the movement is a
good indicator in measuring the low
frequencies, lower than 600 CPM, it will not
detect major frequency problems as can be
caused by damaged bearings or worn out
gears.
For example, assume that we have a blower
coupled by pulleys and bands where the
engine has a normal operational velocity of
3600 RPM. The motor presents a bearing
failure of 0.3 in./sec. at a spinning
frequency (1X RPM).
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Code . . .

As the normal alarm levels for this

LOGARITHMIC AMPLITUDE LOGARITHMIC AMPLITUDE
R
ATO
DIC
ER IN
W
PO
LOGARITHMIC AMPLITUDE

MO
VEM (g)
ENT ON
(mil AT I
s) CE LER
AC
SPEED
FATIGUE INDICATOR

AREA OF SEVERE
SIMILITUDE
EFF
O RT
IND
ICA
T OR
LOGARITHMIC FREQUENCY

COMPARISON OF VIBRATION LEVELS FOR

MOVEMENT, SPEED AND ACCELERATION

equipment are 2 mils, the amplitude at the

FIGURE 1 spinning frequency could be well observed
on a linear spectral scale, while the
vibration at 60,000 CPM will not be
observed adequately.

It's very probable that the analyst will not

If the peak-peak movement is used to
evaluate this equipment and according to
Table 1, we observe that at the frequency
of 60,000 CPM, the spinning vibration will
be only 1,5 mils.
notice the bearing failure with the
movement parameter, but the use of the
velocity spectrum will allow a clear
indication of the spinning frequency and the
bearing failure frequency. The latter is a
cause of major preoccupation even though
the amplitude is similar to the one of
unbalance at the spinning frequency.

However, the spectra obtained in velocity

also have limitations. For example, let's
assume that we have an air centrifugal
turbo compressor that spins at 3580 RPM
and has a 344 tooth motive gear. The gear
frequency (GMF) of this compressor will be
approximately 1,231,500 CPM. In order to
make an adequate observation of the gear
situation, it is necessary to obtain spectra
of at least 2.5 times the gear frequency.

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For this type of equipment, the normal
values that are twice the engine
frequency are 6 G's; on other hand,
when wearing out problems start, this
value can increase ten times.
If we have a vibration level of 60 G's at
2X GMF, which is equivalent in this case
to 2,263,000 CPM, the vibration
velocity at this frequency is 0.089
in./sec. and with a movement of only
0.0007 mil.
Consequently, the best indicator of the
gear state for this kind of equipment is
the acceleration, especially if one
needs to analyze frequencies greater
than 300,000 CPM.
However, the speed spectra have
proven to be the best indicators of
most vibration problems.
Consequently, the alarms analyzed in
this chapter will be defined in peak
units.
The Tables I and II contain values in
peak velocity; however, if one wishes
to use RMS velocity it will only be
necessary to multiply the peak value by
0.07071.
6.4 Problems that can be detected
with vibration analysis
In order to define adequately the
spectral band alarms, it is necessary to
clearly understand which problems can
be detected through the vibration
analysis, the manner in which they are
detected and the level of severity.
During years, many investigations have
taken place to determine the way of
evaluating typical problems, as are the
cases of: unbalance, alignment, bearing
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and gear condition, electrical conditions, etc.
The Nexus A graphs show us a summary of the
most common vibration problem diagnostics.
The nexus A will help to compress the
primordial causes.
In these graphs, one will find typical spectra
of different vibration problems. However,
they will not be necessarily the only ones used
in different failure types.
For example, for the angular lack of alignment
graph, note that while typical spectrum shows
high amplitudes at 1X RPM and 2X RPM in the
axial direction, at times high amplitudes will
be shown at 1X, 2X and 3X RPM which
dominate all the spectra, whether they are
axial or radial readings.
Additionally, there will be equipment that
simultaneously presents various problems, as
can be the case of high unbalance combined
with the mechanical looseness at the base. In
this case, both problems present high
amplitudes at 1X RPM with harmonic multiples
of spinning frequency.
In some graphs, the phases of two points are
presented in order to improve the analyst's
diagnostic.
Hopefully, the Nexus A graphs will help the
analyst diagnose a great variety of equipment
problems. Today, experiments and
investigations are conducted in the field to
complement the information that is presented
in the annexed graphs.
6.5 Vibration global value (GV) specifications
Even today, a lot of investigation is conducted
to establish permissible vibration standards.
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Code . . .

Some international committees, formed ventilators, etc.)

by experienced professors, have studied Classification Vibration in the equipment
the task of formulating the vibration supports (in./sec. peak)
criteria. Very good < 0.07 (1.75 mm/s)
Good < 0.20 (5.00 mm/s)
The International Standard Organization Precaution < 0.50 (13.0 mm/s)
(ISO) establishes the permissible Unacceptable > 0.50 (13.0 mm/s)
vibration levels in accordance with ISO Various intents similar to ISO norms have been
2372, as is shown in: made to offer severity vibration criteria for
different types of equipment. This is
important because even with the same power
Table I. Severity criteria ISO 2372 for there will be variations in the normal vibration
the equipment with the levels.
spinning velocity range from
600 to 12,000 RPM. For example, a reciprocating air compressor
will have different vibration values from those
of a screw compressor. Also, equipment will
Class 1. Small equipment (for example electricalhave different vibration levels depending on
motors up to 20 HP, tool machines,the type and the location of anti-vibrators, the
etc.) natural frequency of the whole equipment,
Classification Vibration in the equipmentthe relation of the center of gravity with
supports (in./sec. peak) respect to the insulators, etc.
Very good < 0.02 (0.50 mm/s)
Good < 0.05 (1.25 mm/s) Consequently, the analyst will have to take
Precaution < 0.13 (3.3 mm/s) into account the type of equipment and its
Unacceptable > 0.13 (3.3 mm/s) assembling for the proper assignation of the
vibration global levels in the predictive
Class 2. Medium size equipment (for examplemaintenance software that is used.
electrical motors up to 100 HP, pumps, etc.)
Classification Vibration in the equipment
supports (in./sec. peak)
In this chapter, we shall use Table II, which
Very good < 0.03 (0.75 mm/s) was developed by James Berry (Technical
Good < 0.08 (2.00 mm/s) Association of Charlotte), it's the best starting
Precaution < 0.20 (5.00 mm/s) point for the criteria definition regarding the
Unacceptable > 0.20 (5.00 mm/s) global vibration levels in in./sec. peak and
mm/sec. peak.
Class 3. Large equipment in cement industry (for
example steam turbines, centrifugalThe table II is the starting point in defining the
compressors, etc.) vibration criteria; in no way should it be taken
Classification Vibration in the equipmentas a conclusive reference to equipment's
supports (in./sec. peak) condition. These initial criteria should be
Very good < 0.05 (1.25 mm/s) followed by the user's further analysis after
Good < 0.13 (3.30 mm/s) having analyzed the vibration indicators at
Precaution < 0.30 (7.50 mm/s) each measurement point in the system.
Unacceptable > 0.30 (7.50 mm/s)
In the Table II, there are three vibration level
Class 4. Large equipment in cement industry (for
example large turbo generators, largesections: "GOOD", "REGULAR" and "ALARM".

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After the global level revision of the
vibration in equipment in good
condition, it is probable that most of
the points are located in the good or
regular section. However, even though
all the measurement points are located
in the acceptable section, there is a
possibility that the equipment has
serious functional problems.
Therefore, it is in this situation that
spectral band alarms will be used. The
global vibration values presented in
Table II will be used as direct indicators
in the definition of alarm levels in the
Table III sections.
6.6 Alarm levels and spectral band
width specifications
The Table III shows the definition of the
alarms and spectral bandwidths for
various types of equipment, as well as
different configurations when using
predictive maintenance software that
allows the formation of at least six
spectral bands.
The CSI Master Trend software
facilitates the formation of no more
than 12 spectral bands, consequently
this Table can be used for the same
purpose, and even new bands can be
added if necessary.
Before using Table III, the user should
identify in the Table II the type of
equipment in question in order to
define the global value that will be
used for this equipment. This
information is the global vibration value
which will be used directly in Table III.
If the equipment selected for
examination is not included in Table II,
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it will be necessary to consult the supplier of
the equipment in order to obtain the
necessary information regarding the
acceptable vibration levels.
If this information is not received, one should
use the equipment vibration levels of the most
similar type.
In Table III “DESCRIPTION” there are various
sections. The "BAND'S MINIMUM FREQUENCY"
defines at what frequency each band should
initiate. It is important to notice that this
minimum band frequency starts at 1% of the
FMAX instead of 0 CPM.
This frequency does not initiate at 0 CPM
because most data collectors and spectral
analyzers have a "noise" in the area of the first
three spectral lines, especially when the data
is collected with an accelerometer and are
converted into speed with digital integration.
The "MAXIMUM BAND FREQUENCY" specifies the
maximum frequency of each band. We shall
see bellow a section "BAND ALARMS" which
defines the alarm level as a total value
percentage (in some cases a direct value is
used) of each band.
In conclusion, at the end of the column, the
"FREQUENCY RANGES ON A BAND" are defined
to allow the user to distinguish the failure
type that can occur in every frequency band.
6.7 Case A - General equipment with cog
tooth or blade bearings
The case A is applicable to a variety of driving
as well as driven equipment of rotating kind
which have ball and roller bearings or needle
type supports.
Before using the Case A from Table III, it will
be necessary to identify the type of equipment
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in Table II in order to use the global
vibration value defined in Table II.
The equipment's Global Value (VG)
obtained in Table II will be substituted
in each spectral band by taking the
percentage that corresponds to each
band.
It is important to note in the Case A
that for the equipment with spinning
velocity ranging from 500 to 999 RPM,
the FMAX should be taken at 60X RPM.
The reason for this procedure is to
ensure that the first stages of bearing
damage can be observed, especially at
natural speeds of the equipment.
This range prevents that only the final
stages of the bearing failure are
observed.
If in the Case A, the FMAX ranges are
set too low, the important high
frequency information will be lost; and
consequently, we shall not have the
information pertinent to the first stages
of bearing failure. In the Nexus A, the
typical spectra of the initial bearing
failure are presented.
On the other hand, if the FMAX ranges
are defined too high, one will have a
low spectral resolution, which could
cause confusion at the time of
elaborating a diagnostic.
In the second place, all the information
in the area of low frequencies as are
unbalance, lack of alignment and the
sub-harmonic waves will be piled up on
the spectrum's left side, losing the
potential information for diagnostics.
In general, there is a rule for the FMAX
definition: maintain it as low as
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possible without losing any important
information.
As the last point in case A, note that each
defined band has a specific purpose in the
area that it covers. For example, the band A
covers the sub-synchronous vibration area that
is fundamental for the spin. In this area are
located tabulated problems: looseness,
bearing box spinning frequency, unbalance,
bent axle, eccentricity, etc.
The bands 2 and 3 cover the two harmonic
waves (2X and 3X RPM) where potential
problems can be found as are slipping,
mechanical looseness, etc. The band 4 covers
the fundamental frequencies of most bearing
failures (BPFI, BPFO and BSF).
In a similar way, bands 5 and 6 cover areas of
bearing's natural frequencies as well as the
harmonic waves of the fundamental bearing
frequencies.
6.8 Case B - General equipment like flat
strengthening plates without cog teeth
or blades.
The case B is similar to case A but with the
difference that this case could be applied to
equipment with flat strengthening plates. The
cases in which the motor has bearings and the
driven equipment has flat strengthening
plates, then, the case A should be applied to
the motor, while the case B should be applied
to the equipment which is driven.
It is important to note that FMAX for the flat
strengthening plates is of only 20X RPM in
comparison with 50X or 60X RPM for the
equipment with bearings which present areas
of high frequency.
Additionally, the flat strengthening plates
could cause serious problems in the area of
sub-synchronous frequency, as is the case with
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oil squirts. Consequently, the
frequency range should be minor and
one should have a good resolution in
the sub-synchronous area in order to
detect correctly these problems.
For this reason, the band 1 is
exclusively selected for the detection
of sub-synchronous vibration. The
maximum percentage of global value is
assigned to band 2 while a very low
value is assigned to the band 6 because
in its area the vibration will be
insignificant.
6.9 Case C - Gear box, high frequency
points with a known number of
teeth
The gearboxes will need two
measurement definitions in some places
due to a possible problem with
unbalance, lack of alignment, looseness
in the area of low frequency, as well as
frequencies generated by the gears in
the area of high frequencies.
Taking into account the
aforementioned and with the goal of
obtaining the best possible information
in the area of equipment's condition, it
will be necessary to:
a) Define in each axle support points
that consist of the gear boxes, alarms
and the frequencies that correspond to
cases A and B, depending on the
support types, bearings or
strengthening plates that they have
respectively.
b) Define the second pair of alarms and
spectral bands with a 2.75X GMF (gear
frequency) at the points closest to the
gears, preferably in the direction of
their common contact points.
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It is very common that the second gear
harmonic frequency has higher vibration
values than the fundamental 1X GMF when
there are gear problems. Consequently, the
second harmonic frequency and its lateral
bands should be covered. In addition, some
gear looseness cases will be observed in the
GMF harmonic wave area.
It will not be absolutely necessary to define
the two alarm pairs of the spectral bands for
each measurement point. However, it is
recommended to check from time to time the
points whose global values have increased
considerably, and no increase has been noted
in the low frequencies.
In the gear boxes with various reduction
stages, it is important to take into account the
number of teeth of each analyzed gear, as
well as the spinning frequency of each axle,
especially for the definition of the bands
required for A and B cases and for the high
gear-frequency points.
6.10 Case D - Gear boxes, high frequency
points with an unknown number of teeth
Unfortunately, in the majority of the
gearboxes, the teeth number is not known. In
some gears, the spinning frequency of each
axle is also unknown.
Despite these problems, it is possible to
effectively define the spectral band alarms,
which can be used temporarily, while the
correct teeth number and spinning frequency
information of each monitored point is sought.
In the case D, a maximum frequency of 160X
RPM is specified; it will be applied at each
measurement point on each axle that contains
gears.
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If the spinning frequency of each axle is
unknown, it is recommended to
provisionally define spinning
frequencies for each axle considering
the increase (or decrease, depending
on the specific case) in the same
proportion for each axle based on the
Increasing or Decreasing Factors data
that is specified on the gear box plate.
Once the teeth number for each gear
and the axle spinning frequencies that
contain the gears are known, the
charge side of the motor will need to
be modified, making sure to use at
least 1,600 resolution lines to separate
adequately the alarms and spectral
bands of this equipment, following the
procedures seen in case C.
6.11 Case E - Measurement point for
the rotor rod passage frequency
in induction motors
The specific purpose for adding this
point in each induction motor is to
detect the first two harmonic rotor rod
passage frequencies (RBPF = rod no. X
motor spinning freq.), and the lateral
bands of double electric line frequency
(7200 CPM) that normally accompany
the rod frequency.
When high rotor rod passage frequency
amplitudes or the second harmonic
wave are detected, one suspects that a
loose rod and/or a motor eccentricity is
present; particularly when these
frequencies are followed with 2X
electric frequency lateral bands and/or
2X slipping frequency.
In the Nexus A, the induction motor
functions with regard to electric
vibration are explained more clearly.
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This high frequency measurement point for the
detection of rotor rod problems is normally
defined on the horizontal axle and on the back
of the induction motors, using as a minimum
of 1600 resolution lines to easily observe the
lateral bands.
It is important to remember that this is an
additional point to those already established
in the cases A and B, depending on the motor
support type.
Due to the unknown number of rotor rods in
most motors, it was decided to determine the
maximum velocity of 240,000 CPM in order to
cover most motors seen on the market, in
which the number of rods various from 37 to
70.
6.12 Case F - Low frequency measurement
point for the detection of electric
frequency.
The fundamental purpose of this additional
point in each induction motor is to separate
adequately the vibration frequencies
generated by mechanical failure induced by an
electrical problem.
The valuable information in the low frequency
spectrum and high resolution is found in the
area of 3,600 CPM, equivalent to the electric
frequency, as well as the double value of this
frequency, 7,200 CPM.
It is common in the maintenance predictive
systems to find frequencies of 7,200 CPM, its
amplitude is high and there is a possibility of
an electric problem in the motor as can be the
case of the stator eccentricity or cracked rods
in the rotor. In the Nexus A, these symptoms
are explained in detail.
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The measurement point additional to
those configured in cases A or B should
be assigned to the horizontal position in
the mechanic-electric problems.
6.13 Case G - Special equipment
The purpose of this section is to cover
various types of special equipment that
for some reason requires different
configuration of spectral bands from
those seen in cases A and B, Table III.
For example, the primary objective in
specifically defining the bands of
centrifugal equipment (pumps and
ventilators) defined in the Types 1
through 4 in case G is to separate the
cog tooth and blade passage frequency
from the bearing failure frequency.
However, the amplitudes permitted for
the cog tooth or blade passage
frequency will not be sufficient for the
bearing failure frequency, they will be
excessively high to detect bearing
failures.
Consequently, in the cases where one
or various typical bearing failures and
the cog tooth passage are in the same
band, it will be impossible to separate
alarms levels of the two vibration
sources.
Type 1 - Centrifugal equipment with a
known number of cog teeth or blades
and bearings
If the number of blades, cog teeth or
lobes in a ventilator, pump or
compressor is known, it will be possible
to add a separate band to record the
passage frequency of the cog teeth,
blades or lobes (BPF). In this band, a
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higher alarm level will be defined than it was
defined in the levels programmed for the
bearing problem detection.
In Type 1, Table III, the band 4 has a
fundamental frequency for the cog tooth
passage and the first harmonic wave of lateral
bands that could be detected above or bellow
this warping frequency.
On this band, the permitted vibration level is
70% of the Global Value (VG). Bands 3 and 5,
adjacent to band 4, will have minor values for
the bearing problem detection. In addition to
bearings low harmonic waves, the band 5 will
detect cog tooth harmonic frequency wave
that is an indicator of the pulsing flow
problem.
Type 2 - Centrifugal equipment with an
unknown number of cog teeth or blades and
bearings
This configuration will include the equipment
for which we know that there are cog teeth
and bearing supports, but the exact number of
cog teeth or blades is unknown. Different
from the previously mentioned Type 1, the
band 4 will cover the frequencies ranging from
4X to 6X RPM because most of the centrifugal
equipment like pumps and ventilators have
from 4 to 6 blades.
The previous statement is not necessarily true
in all the cases, because the width of this
band can be adjusted.
Once the information about the number of cog
teeth or blades is obtained, it will be
necessary to reconfigure the equipment using
the information from Table 1.
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Type 3 - Centrifugal equipment with
the known number of cog teeth or
blades and flat strengthening plates.
In this case, the maximum frequency
goes up to only 20X RPM, in comparison
with 50X or 60X RPM for equipment
with bearings. The band 5 will be used
to calculate the information generated
by the cog tooth frequency and its
possible bands of the first spinning
frequency harmonic wave.
The alarm level will be 70% of the
Global Value (VG), while the levels of
bands 4 and 6 will be only 30% of the
global value. The maximum frequency
will be defined up to 1.2X the number
of blades (BPF), in the case where this
multiplication is greater than 20X RPM.
Type 4 - Centrifugal equipment with
the unknown number of cog teeth or
blades and flat strengthening plates
In this case, the band 4 will record the
possible cog tooth or blade passage
frequencies for pumps and ventilators.
The band 6 with a range from 10X to
20X RPM will record the cog tooth or
blade passage harmonic wave
frequencies to detect pulsing flow
problems.
It is important to mention again that it
will be necessary to reconfigure the
equipment with the information from
Type 3, once the information about the
number of cog teeth or blades is
obtained.
6.14 The detection of high frequency
in the bearing condition
diagnostics
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In addition to the use of different alarms and
spectral bands in the case of equipment with
bearings, there is an additional predictive
maintenance software tool called High
Frequency Detection (HFD).
This bearing condition indicator is based on
the detection of acceleration levels in the high
frequency area, typically from 5,000 to 20,000
Hz. The value obtained with these filters will
be expressed in acceleration units (G's), and
the tendency of this value will help to
determine the analyzed bearing condition.
When a bearing starts to deteriorate, the balls
and rollers will start to fall into the
microscopic "potholes" created on the track,
and thus exciting the bearings and their
components natural frequencies in a high
frequency area.
It will be possible to detect with the HFD
these premature deterioration stages in the
fenders, but in the normal spectrum it will be
almost impossible to appreciate the
fundamental bearing failure frequencies in this
deterioration stage.
In the case of CSI, the Master Trend software
allows to define an additional band thanks to
the HFD configuration, it has even pre-
configured the band width and very similar
alarms to those seen in previous sections.
It is recommended in general to place the
value "REGULAR" to 1.5 G's RMS and "ALARM"
level to 3.0 G's RMS. Even though this HFD
parameter is a good indicator of bearings
condition, one should use additional tools as
seen in the case of demodulation (chapter 9)
to confirm the bearings state, especially in the
most critical company equipment.
In addition, the filter HFD will also serve to
detect possible problems caused by lack of
lubrication, the problem occurs because the
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lack of lubrication in the bearings,

especially in the case of grease
lubrication, makes the contact metal-
metal very probable between balls and
tracks, generating very high
frequencies that could be detected
with the HFD.

In case of a subtle increase in the HFD

values between readings, it is
recommended to re-lubricate the
bearings and retake measurements to
see the effects at high frequencies.

In case the values have diminished

considerably, it will be necessary to
retake measurements in 24 hours to
ensure that they did not return to their
previous level. When the HFD go back
to their previous values after this time
lapse, it is very probable that the
bearing is in its initial failing stage.

The adjusting of the accelerometer will

need to be done using a magnetic band
or it should be screwed to the
equipment to obtain reliable HFD
information. In no way should this
measurement be taken with a manual
measuring point accelerometer.

In conclusion, it is important to
remember that in the bearing case, the
natural frequencies do not change with
the increase or decrease in the spinning
frequency of the equipment. This is
important at the moment of spectrum
evaluation with natural bearing
frequencies.

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TABLE II. CRITERIA FOR RANGES IN GLOBAL VALUE VIBRATION CONDITIONS

(VIBRATION VELOCITY, PEAK IN IN./SEC.). See notes bellow:

TYPE OF EQUIPMENT GOOD REGULAR ALARM failure

Alert limit limit
COOLING TOWER TRANSMISSIONS
Long floating axle transmission 0 - .375 .375 - .600 > .600
Pulleys and bands transmission 0 - .275 .275 - .425 > .425
Direct coupling transmission 0 - .200 .200 - .300 > .300
COMPRESSORS
Reciprocating 0 - .325 .325 - .500 > .500
Screws 0 - .275 .275 - .425 > .425
Centrifugal with or without external gear boxes 0 - .200 .200 - .300 > .300
Centrifugal with integrated gear (axial reading) 0 - .200 .200 - .300 > .300
Centrifugal with integrated gear (radial reading) 0 - .150 .150 - .250 > .250

VENTILATORS AND BLOWERS

Rotator lobe 0 - .300 .300 - .450 > 450
Blower fit with pulleys and bands 0 - .275 .275 - .425 > .425
Directly fit ventilators 0 - .250 .250 - .375 > .375
Primary air ventilators 0 - .250 .250 - .375 > .375
Large forced draft ventilators 0 - .200 .200 - .300 > .300
Large induced draft ventilators 0 - .175 .175 - .275 > .275
Ventilators fit on the axle of a motor 0 - .175 .175 - .275 > .275
Axial flow ventilators 0 - .150 .150 - .250 > .250
MOTOR-GENERATOR
Belt coupled 0 - .275 .275 - .425 > .425
coupler coupled 0 - .200 .200 - .250 > .300
COOLING SYSTEM
Reciprocating 0 - .250 .250 - 400 > .400
Open centrifugal 0 - .200 .200 - .300 > .300
Hermetic centrifugal 0 - .150 .150 - .225 > .225
LARGE TURBOGENERATORS
3600 RPM turbo generators 0 - .250 .250 - .400 > .375
1800 RPM turbo generators 0 - .175 .175 - .275 > .275
CENTRIFUGAL PUMPS
Vertical pumps (height ranging from 4 to 7 meters) 0 - .375 .375 - .600 > .600
Vertical pumps (height ranging from 2.5 to 4 meters) 0 - .325 .325 - .500 > .500
Vertical pumps (height ranging from 1.5 to 2.5 meters) 0 - .250 .250 - .400 > .400
Vertical pumps (height ranging from 0 to 1.5 meters) 0 - .200 .200 - .300 > .300
General use horizontal pumps 0 - .200 .200 - .300 > .300
Boiler supplier pump 0 - .200 .200 - .300 > .300
Hydraulic pumps 0 - .125 .125 - .200 > .200
TOOL-MACHINES
Motor 0 - .100 .100 - .175 > .175
entrance to the gear box 0 - .150 .150 - .225 > .225
Exit from the gear box 0 - .100 .100 - .175 > .175
Spindles
a. Cutting operations 0 - .075 .075 - .125 > .125
b. Platter finish 0 - .050 .050 - .075 > .075
c. Critical tolerance platter 0 - .030 .030 - .050 > .050

Notes:
1. Assuming an equipment spinning velocity from 500 to 60,000 CPM.
2. Assuming readings taken with accelerometer or velocity seismic sensor closest to bearings or strengthening plates.
3. Assuming that the equipment is not on insulators (for insulated equipment increase the alarm level 30 to 50%.
4. Set the alarms of similar motors to driven equipment.
5. Set the external gear box alarms 25% higher than the levels of driven equipment

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VIBRATION MANUAL
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TABLE II. CRITERIA FOR RANGES IN GLOBAL VALUE VIBRATION CONDITIONS

(VIBRATION VELOCITY, PEAK IN MM./SEC.). See notes bellow:

TYPE OF EQUIPMENT GOOD REGULAR ALARM failure

Alert limit limit
COOLING TOWER TRANSMISSIONS
Long floating axle transmission 0 - 9.50 9.50 - 15.25 > 15.25
Pulleys and bands transmission 0 - 7.00 7.00 - 10.80 > 10.80
Direct coupling transmission 0 - 5.00 5.00 - 7.50 > 7.50
COMPRESSORS
Reciprocating 0 - 8.25 8.25 - 12.70 > 12.70
Screws 0 - 7.00 7.00- 10.80 > 10.80
Centrifugal with or without external gear boxes 0 - 5.00 5.00 - 7.50 > 7.50
Centrifugal with integrated gear (axial reading) 0 - 5.00 5.00 - 7.50 > 7.50
Centrifugal with integrated gear (radial reading) 0 - 3.80 3.80 - 6.40 > 6.40
VENTILATORS AND BLOWERS
Rotator lobe 0 - 7.50 7.50 - 11.50 > 11.50
Blower fit with pulleys and bands 0 - 7.00 7.00 - 10.80 > 10.80
Directly fit ventilators 0 - 6.40 6.40 - 9.50 > 9.50
Primary air ventilators 0 - 6.40 6.40 - 9.50 > 9.50
Large forced draft ventilators 0 - 5.00 5.00 - 7.50 > 7.50
Large induced draft ventilators 0 - 4.50 4.50 - 7.00 > 7.00
Ventilators fit on the axle of a motor 0 - 4.50 4.50 - 7.00 > 7.00
Axial flow ventilators 0 - 3.80 3.80 - 6.40 > 6.40
MOTOR-GENERATOR
Belt coupled 0 - 7.00 7.00 - 10.80 > 10.80
coupler coupled 0 - 5.00 5.00 - 7.50 > 7.50
COOLING SYSTEM
Reciprocating 0 - 6.40 6.40 - 10.00 > 10.00
Open centrifugal 0 - 5.00 5.00 - 7.50 > 7.50
Hermetic centrifugal 0 - 3.80 3.80 - 5.70 > 5.70
LARGE TURBOGENERATORS
3600 RPM turbo generators 0 - 6.40 6.40 - 9.50 > 9.50
1800 RPM turbo generators 0 - 4.50 4.50 - 7.00 > 7.00
CENTRIFUGAL PUMPS
Vertical pumps (height ranging from 4 to 7 meters) 0 - 9.50 9.50 - 15.25 > 15.25
Vertical pumps (height ranging from 2.5 to 4 meters) 0 - 8.25 8.25 - 12.70 > 12.70
Vertical pumps (height ranging from 1.5 to 2.5 meters) 0 - 6.40 6.40 - 10.00 > 10.00
Vertical pumps (height ranging from 0 to 1.5 meters) 0 - 5.00 5.00 - 7.50 > 7.50
General use horizontal pumps 0 - 5.00 5.00 - 7.50 > 7.50
Boiler supplier pump 0 - 5.00 5.00 - 7.50 > 7.50
Hydraulic pumps 0 - 3.20 3.20 - 5.00 > 5.00
TOOL-MACHINES
0 - 5.50 2.50 - 4.50 > 4.50
Motor 0 - 3.80 3.80 - 5.70 > 5.70
entrance to the gear box 0 - 2.50 2.50 - 4.50 > 4.50
Exit from the gear box
Spindles 0 - 2.00 2.00 - 3.20 > .3.20
a. Cutting operations 0 - 1.25 1.25 - 2.00 > .2.00
b. Platter finish 0 - 0.75 0.75 - 1.25 > 1.25
c. Critical tolerance platter

Notes:
1. Assuming an equipment spinning velocity from 500 to 60,000 CPM.
2. Assuming readings taken with accelerometer or velocity seismic sensor closest to bearings or strengthening plates.
3. Assuming that the equipment is not on insulators (for insulated equipment increase the alarm level 30 to 50%.
4. Set the alarms of similar motors to driven equipment.
5. Set the external gearbox alarms 25% higher than the levels of driven equipment.

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TABLE III. RECOMMENDED SPECTRAL BAND ALARM SYSTEM SPECIFICATIONS FOR VARIOUS EQUIPMENTS
(See notes 1 and 2 bellow).
(PEAK VELOCITY BANDS FOR NO INSULATED EQUIPMENT BOX MEASUREMENTS AND AT A VELOCITY GREATER THAN 500 RPM).

CASE A.
MACHINES IN GENERAL WITH BEARINGS WITHOUT COG TEETH OR BLADES --Set FMAX = 50X RPM (if the spinning velocity < 1500RPM see case A notes)
DESCRIPTION BAND 1 BAND 2 BAND 3 BAND 4 BAND 5 BAND 6

MINIMUM BAND FREQ. 5% Fmax 1.2X RPM 2.2X RPM 3.2X RPM 12.2X RPM 50% Fmax
MAXIMUM BAND FREQ. 1.2X RPM 2.2X RPM 3.2X RPM 12.2X RPM 50% Fmax 100% Fmax
ALARM BANDS 90% OF VG ALARM 50% OF VG ALARM 40% OF VG 30% OF VG ALARM 25% OF VG ALARM 20% OF VG ALARM
ALARM
FREQUENCY RANGE COVERED BY Subsynchronous freq. 1.5 - 2.0X RPM Fundamental Low bearing harmonic High bearing harmonic
THE BAND and 2.5 -3.0X RPM frequencies wave wave
1X RPM for failing bearings frequency frequencies and
natural
bearing frequencies

NOTE: To obtain alarm values of Global Values (VG) go back to TABLE II "CRITERIA FOR RANGES...".
NOTE: FMAX = Spectral maximum frequency
NOTE: If the spinning velocity is between 500 and 999 RPM set the FMAX = 60X RPM to detect possible natural bearing frequencies.

CASE B.
MACHINES IN GENERAL WITH FLAT STRENGTHENING PLATES WITHOUT COG TEETH OR BLADES --Set FMAX = 20X RPM

DESCRIPTION BAND 1 BAND 2 BAND 3 BAND 4 BAND 5 BAND 6

MINIMUM BAND FREQ. 1% Fmax 0.8X RPM 1.8X RPM 2.8X RPM 3.8X RPM 10.2X RPM
MAXIMUM BAND FREQ. 0.8X RPM 1.8X RPM 2.8X RPM 3.8X RPM 10.2X RPM 100% Fmax
ALARM BANDS 30% OF VG ALARM 90% OF VG ALARM 50% OF VG 40% OF VG ALARM 35% OF VG ALARM 20% OF VG ALARM
ALARM
FREQUENCY RANGE COVERED BY Subsynchronous band 1X - 1.5X RPM 3X - 3.5X RPM 4X - 10X RPM 10.5X - Fmax
THE BAND 2X - 2.5X RPM

NOTES:
1. These spectral band alarm specifications are applied to standard process and service equipment as are centrifugal pumps, blowers, motors, forced and induced draft ventilators, generators, coolers, centrifugal
compressors, vacuum pumps, reducers, etc.

2. These specifications are not applicable to reciprocating equipment, diesel motors, gas turbines, great power generators, exciters, pulverizes, etc. The spectral bands for this type of equipment should be designed
by the user after obtaining and analyzing spectra.

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TABLE III. RECOMMENDED SPECTRAL BAND ALARM SYSTEM SPECIFICATIONS FOR VARIOUS EQUIPMENT
(See notes 1 and 2 bellow).
(PEAK VELOCITY BANDS FOR NO INSULATED EQUIPMENT BOX MEASUREMENTS AND AT A VELOCITY GREATER THAN 500 RPM).

CASE C.
GEAR BOXES, HIGH FREQUENCY POINTS WITH KNOWN NUMBER OF TEETH --Set FMAX = 2.75X RPM Gear Freq. (GMF)- See case C note)

DESCRIPTION BAND 1 BAND 2 BAND 3 BAND 4 BAND 5 BAND 6

MINIMUM BAND FREQ. 1% Fmax 0.1X GMF 0.25X GMF 0.75X GMF 1.25X GMF 1.75X GMF
MAXIMUM BAND FREQ. 0.1X GMF 0.25X GMF 0.75X GMF 1.25X GMF 1.75X GMF 100% MAX
ALARM BANDS 90% OF VG ALARM 40% OF VG ALARM 30% OF VG 70% OF VG GMF 30% OF VG ALARM 50% OF VG ALARM
ALARM
FREQUENCY RANGE COVERED BY Low harmonic waves High harmonic GMF and its 1.5X GMF and its 2X GMF, 2.5X GMF and
THE BAND waves 0.5X GMF and its lateral bands lateral bands its
lateral bands lateral bands

NOTE: In gear boxes, it will be necessary to specify if there are points with high frequency ranges in addition to the normal frequency range points, as was
described in cases A and B. Place the sensor closest to the axle gear that should be checked. It is important to remember that the natural acceleration
frequency can be excited, consequently it is recommended to use the magnetic disc or to place fast switch breakers to avoid these problems.
NOTE: GMF = gear frequency = No. of gear teeth in question multiplied by its spinning frequency.

CASE D.
GEAR BOX, HIGH FREQUENCY POINTS WITH UNKNOWN NUMBER OF TEETH --Set FMAX = 160X RPM of the axle to be checked--See note C

DESCRIPTION BAND 1 BAND 2 BAND 3 BAND 4 BAND 5 BAND 6

MINIMUM BAND FREQ. 1% Fmax 10X RPM 40X RPM 70X RPM 100X RPM 130X RPM
MAXIMUM BAND FREQ. 10X RPM 40X RPM 70X RPM 100X RPM 130X RPM 100% Fmax
ALARM BANDS 70% OF VG ALARM 60% OF VG ALARM 60% OF VG 60% OF VG ALARM 40% OF VG ALARM 40% OF VG ALARM
10 - 40X RPM ALARM
FREQUENCY RANGE COVERED BY 1.6 - 10X RPM 70 - 100X RPM 100 - 130X RPM 130X - Fmax
THE BAND 40 - 70X RPM

NOTE: The 160X RPM frequency range should be applied to each axle that is checked, taking into account the spinning velocity or each axle. One should additionally take spectra
with the cases A and B frequency ranges. Once the number of gear teeth is acquired, immediately replace the spectral band alarm levels with those of the case C.

NOTES:
1. These spectral band alarm specifications are applied to standard process and service equipment as are centrifugal pumps, blowers, motors, forced and induced draft ventilators,
generators, coolers, centrifugal compressors, vacuum pumps, reducers, etc.

2. These specifications are not applicable to reciprocating equipment, diesel motors, gas turbines, great power generators, exciters, pulverizers, etc. The spectral bands for this type
of equipment should be designed by the user after obtaining and analyzing spectra.

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TABLE III. RECOMMENDED SPECTRAL BAND ALARM SYSTEM SPECIFICATIONS FOR VARIOUS EQUIPMENT
(See notes 1 and 2 bellow).
(PEAK VELOCITY BANDS FOR NO INSULATED EQUIPMENT BOX MEASUREMENTS AND AT A VELOCITY GREATER THAN 500 RPM).

CASE E.
FREQUENCY MEASUREMENT POINTS FOR THE INDUCTION MOTOR ROTOR ROD --Set FMAX = 240,000 RPM (See case E note)

DESCRIPTION BAND 1 BAND 2 BAND 3 BAND 4 BAND 5 BAND 6

MINIMUM BAND FREQ. 30,000 RPM 65,000 RPM 100,000 RPM 135,000 RPM 170,000 RPM 205,000 RPM
MAXIMUM BAND FREQ. 65,000 RPM 100,000 RPM 135,000 RPM 170,000 RPM 205,000 RPM 240,000 RPM
ALARM BANDS .08 in./sec. .06 in./sec. 0.06 in./sec. 0.06 in./sec. 0.06 in./sec. 0.06 in./sec.
(2mm/sec.) (1.5 mm/sec.) (1.5 mm/sec.) (1.5 mm/sec.) (1.5 mm/sec.) (1.5 mm/sec.)
FREQUENCY RANGE COVERED BY 65K - 100K 170K - 205K
THE BAND 30K - 65K 100K - 135K 135K - 170K 205K - 240K

NOTE: The purpose of including this additional point in horizontal position on the back of the motor is to detect possible rotor motor passage frequencies and
the appearance of its lateral bands which are twice higher than the electric frequency. This case is applicable to spinning velocity motors which range from
900 to 3600 RPM. The transducer should be well installed, using the magnetic base or quick connection.

CASE F.
LOW FREQUENCY MEASUREMENT POINTS TO DETECT ELECTRIC FREQUENCY --Set FMAX = 12,000 RPM (600 to 3600 RPM motors)

DESCRIPTION BAND 1 BAND 2 BAND 3 BAND 4 BAND 5 BAND 6

MINIMUM BAND FREQ. 240 RPM 2,000 RPM 4,000 RPM 6,000 RPM 8,000 RPM 10,000 RPM
MAXIMUM BAND FREQ. 2,000 RPM 4,000 RPM 6,000 RPM 8,000 RPM 10,000 RPM 12,000 RPM
ALARM BANDS
90% OF VG ALARM 50% OF VG ALARM 50% OF VG 35% OF VG ALARM 30% OF VG ALARM 30% OF VG ALARM
FREQUENCY RANGE COVERED 30% OF VG ALARM 90% OF VG ALARM ALARM
BY THE BAND
120 to 2000 RPM motors
2000 to 4000 RPM motors
NOTE: The purpose of including this additional point in the horizontal position on the motor's charge side is to separate mechanic from electric peaks,
especially in the area of 1X RPM and twice the electric frequency (7,200 RPM for Mexico).

NOTES:
1. These spectral band alarm specifications are applied to standard process and service equipment as are centrifugal pumps, blowers, motors, forced and induced
draft ventilators, generators, coolers, centrifugal compressors, vacuum pumps, reducers, etc.

2. These specifications are not applicable to reciprocating equipment, diesel motors, gas turbines, great power generators, exciters, pulverizers, etc. The spectral
bands for this type of equipment should be designed by the user after obtaining and analyzing spectra.

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TABLE III. RECOMMENDED SPECTRAL BAND ALARM SYSTEM SPECIFICATIONS FOR VARIOUS EQUIPMENT
(See notes 1 and 2 bellow).
(PEAK VELOCITY BANDS FOR NO INSULATED EQUIPMENT BOX MEASUREMENTS AND AT A VELOCITY GREATER THAN 500 RPM).

CASE G. SPECIAL MACHINES

TYPE 1. CENTRIFUGAL MACHINES WITH THE KNOWN NUMBER OF COG TEETH OR BLADES AND BEARINGS-- Set FMAX = 50X RPM (See notes)
DESCRIPTION BAND 1 BAND 2 BAND 3 BAND 4 BAND 5 BAND 6
5% Fmax 1.2X RPM 2.2X RPM BPF - 1.2X RPM* BPF + 1.2X RPM* 50% Fmax
MINIMUM BAND FREQ. 1.2X RPM 2.2X RPM BPF - 1.2X RPM* BPF + 1.2X RPM* 50% Fmax 100% Fmax
MAXIMUM BAND FREQ. 90% OF VG ALARM 50% OF VG ALARM 40% OF VG 70% OF VG ALARM 35% OF VG ALARM 20% OF VG ALARM
ALARM BANDS ALARM
Subsynchronous freq. 1.5 - 2.0X RPM Cog tooth and blade Bearing's low harmonic Bearing's high
FREQUENCY RANGE COVERED BY and 2.5X passing frequency wave harmonic wave
THE BAND 1X RPM Fundamental (BPF) frequency frequencies and
frequencies natural
for failing bearing frequencies
bearings

NOTE: "BPF" = Passing cog bearing or blade freq. = No. of cog bearings or blades multiplied by spinning RPM.
NOTE: If the spinning velocity is between 500 and 999 RPM set the FMAX = 60X RPM to detect possible bearing's natural frequencies.

CASE G. SPECIAL MACHINES

TYPE 2. CENTRIFUGAL MACHINES WITH THE UNKNOWN NUMBER OF COG TEETH OR BLADES AND BEARINGS-- Set FMAX = 50X RPM (See notes)

DESCRIPTION BAND 1 BAND 2 BAND 3 BAND 4 BAND 5 BAND 6

MINIMUM BAND FREQ. 0.5% Fmax 1.2X RPM 2.2X RPM 3.2X RPM 6.8X RPM 50% Fmax
MAXIMUM BAND FREQ. 1.2X RPM 2.2X RPM 3.2X RPM 6.8X RPM 50% Fmax 100% Fmax
ALARM BANDS 90% OF VG ALARM 50% OF VG ALARM 40% OF VG 60% OF VG ALARM 35% OF VG ALARM 20% OF VG ALARM
ALARM
FREQUENCY RANGE COVERED BY Subsynchronous freq. 1.5 - 2.0X RPM Possible cog tooth and Bearing's low harmonic Bearing's high
THE BAND and 2.5 -3.0X RPM blade passing wave harmonic wave
1X RPM frequencies (BPF) frequency frequencies and
for pumps and natural
ventilators bearing frequencies

NOTE: Once the number of cog teeth or blades is obtained, replace these spectral band alarm levels with those from type 1.
NOTE: If the spinning velocity is between 500 and 999 RPM set the FMAX = 60X RPM to detect possible natural bearing frequencies.

NOTES:
1. These spectral band alarm specifications are applied to standard process and service equipment as are centrifugal pumps, blowers, motors, forced and induced draft ventilators,
generators, coolers, centrifugal compressors, vacuum pumps, reducers, etc.

2. These specifications are not applicable to reciprocating equipment, diesel motors, gas turbines, great power generator, exciters, pulverizers, etc. The spectral bands for this type of
equipment should be designed by the user after obtaining and analyzing spectra.

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TABLE III. RECOMMENDED SPECTRAL BAND ALARM SYSTEM SPECIFICATIONS FOR VARIOUS EQUIPMENT
(See notes 1 and 2 bellow).
(PEAK VELOCITY BANDS FOR NO INSULATED EQUIPMENT BOX MEASUREMENTS AND AT A VELOCITY GREATER THAN 500 RPM).

CASE G. SPECIAL MACHINES

TYPE 3. CENTRIFUGAL MACHINES WITH THE KNOWN NUMBER OF COG TEETH OR BLADES AND FLAT STRENGTHENING PLATES-- Set FMAX = 20X RPM or 1.2X
BPF

DESCRIPTION BAND 1 BAND 2 BAND 3 BAND 4 BAND 5 BAND 6

MINIMUM BAND FREQ. 0.1% Fmax 0.8X RPM 1.8X RPM 3.8X RPM BPF - 1.2X RPM* BPF + 1.2X RPM*
MAXIMUM BAND FREQ. 0.8X RPM 1.8X RPM 3.8X RPM BPF - 1.2X RPM* BPF + 1.2X RPM* 100% Fmax
ALARM BANDS 30% OF VG ALARM 90% OF VG ALARM 50% OF VG 30% OF VG ALARM 70% OF VG ALARM 30% OF VG ALARM
ALARM
FREQUENCY RANGE COVERED BY Subsynchronous band 1X - 1.5X RPM 4X - Low spinning Cod tooth or blade High spinning
THE BAND 2X - 3.5X RPM harmonic wave passing frequency harmonic wave
frequency (BPF) and lateral 1X frequency
bands.

* NOTE: "BPF" = Passing cog bearing or blade freq. = No. of cog bearings or blades multiplied by spinning RPM.

CASE G. SPECIAL MACHINES

TYPE 4. CENTRIFUGAL MACHINES WITH THE UNKNOWN NUMBER OF COG TEETH OR BLADES AND BEARINGS-- Set FMAX = 20X RPM
DESCRIPTION BAND 1 BAND 2 BAND 3 BAND 4 BAND 5 BAND 6
MINIMUM BAND FREQ. 1% Fmax 0.8X RPM 1.8X RPM 3.8X RPM 6.8X RPM 9.8X RPM
MAXIMUM BAND FREQ. 0.8X RPM 1.8X RPM 3.8X RPM 6.8X RPM 9.8X RPM 100% Fmax
ALARM BANDS 30% OF VG ALARM 90% OF VG ALARM 50% OF VG 70% OF VG ALARM 25% OF VG ALARM 30% OF VG ALARM
ALARM
FREQUENCY RANGE COVERED BY Subsynchronous band 1X - 1.5X RPM 4X - 6.5X RPM 7X - 9.5X RPM 10X - Fmax
THE BAND 2X - 3.5X RPM

NOTE: Once the number of cog teeth or blades is obtained, replace these spectral band alarm levels with those from type 3.

NOTES:
1. These spectral band alarm specifications are applied to standard process and service equipment as are centrifugal pumps, blowers, motors, forced and induced draft ventilators,
generators, coolers, centrifugal compressors, vacuum pumps, reducers, etc.

2. These specifications are not applicable to reciprocating equipment, diesel motors, gas turbines, great power generators, exciters, pulverizers, etc. The spectral bands for this type
of equipment should be designed by the user after obtaining and analyzing spectra.

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VIBRATION MANUAL
OPERATIONS/ MAINTENANCE
CHAPTER 7
Principles for planning
monitoring routes
7.1 Introduction
An important part of the Predictive
Maintenance System based on the vibration
analysis is the planning of monitoring
routes. Various aspects will influence an
adequate planning of monitoring routes.
In this chapter, we shall mention the most
important aspects that should be taken into
account when implementing the monitoring
routes, as well as general principles for the
selection of monitoring points on the
equipment, adequate mounting of vibration
transducers and the principles for storing
obtained information.
7.2 The principles for correct mounting of
vibration transducers
Today, there are three types of transducers,
which are used to measure vibration levels.
These three types of transducers contain
movement, velocity and acceleration
sensors.
The three systems are based on the
principle of transforming the mechanical
vibration into an analog electrical signal
that represents the mechanical movement.
Even though the three systems have their
particular characteristics and applications,
in this chapter we shall focus on the
description of the accelerometer and its
different forms of mounting because the
transducers cover most of the diagnostic
applications for equipment problems.
31/12/11
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We do not intend at all to exclude the
movement and velocity transducers, but
due to their limited applications they will
not be analyzed in this manual. In case one
needs information about them, necessary
bibliography will be annexed to this manual.
7.2.1 Accelerometer description
The accelerometers transform the mechanic
movement into an analog signal
proportional to the vibration acceleration in
the system. Most of the accelerometers use
piezoelectric materials (generally quartz or
polycrystalline ceramics) as the main
sensitive transducer component.
The quartz is the most durable and it has
smaller signal vibrations with temperature
changes. The piezoelectric material
produces an electric voltage when it is
exposed to an external force. The
material's atoms are compressed and the
electrons are moved creating a voltage
proportional to the force.
In figure 1, the "compression mode"
accelerometer is shown. A mass is pressed
against a piezoelectric material to produce
a reference force.
When an accelerometer is submitted to a
vibration force (equivalent to the mass
multiplied by acceleration), this force is
added to and subtracted from the reference
generated by the screw inserted into the
piezoelectric crystal, producing a voltage
proportional to the change in force.
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VIBRATION MANUAL
OPERATIONS/ MAINTENANCE
inserted screw
inertia mass used
as reference
piezoelectric crystal
Figure 1. Compression type accelerometer
This accelerometer mechanism will have its
natural, operational frequency that will
depend on the installed mass and the
constant spring of the system. The
frequency range is limited to 10% of the
natural frequency.
The high frequency accelerometers (greater
than 10 KHz) are usually small, while the
low frequency accelerometers (0.001 at 1
KHz) are usually large and heavy.
The advantages of vibration reading
accelerometers are:
- They take acceleration readings, which is
an advantage when it is necessary to
measure bearing failure and gear frequency.
- They are small.
- They are light.
- They are economical.
- They have a wide frequency range.
7.2.2 Accelerometer mounting types and
their frequency response
The accelerometers can be mounted on
equipment using threaded screws, quick
connectors, magnetic bases or tracing
points connected to the accelerometer for
the manual data taking. The adequate
mount type will be chosen for each usage
taking into account the frequency range
31/12/11
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that needs to be measured in each specific
case.
When an inadequate mount is used to
measure a certain frequency range, it is
very probable that the acquired signal will
be of low quality.
For example, if it is necessary to take data
of high frequency levels and a manual
tracing point is used, it is very probable
that the high frequency information does
not appear. These details will be discussed
bellow, referring to Table 1.
The direct mounting to equipment is the
most adequate manner for obtaining
reliable vibration readings, while the usage
of quick connectors, magnetic bases and
tracing points will diminish the high
frequency sensitivity.
To obtain the correct, direct mounting on
the equipment, it will be necessary to
adequate the place where the sensor will be
mounted. One should make sure that the
diameter of the equipment is larger than
the sensor's, the measurement place should
be flat in an area not larger than 5
thousandths of an inch, have a finish of at
least 10 micro inches and the thread should
be perpendicular to the base.
On the other hand, the accelerometer
should have a pair of appropriate fasteners
that should have in most cases a value of 26
pounds/inch. However, it will not be
always possible to install screw sensors to
equipment; in those cases, it is
recommended to use fast connectors or
magnetic bases.
The table II shows the frequency response
curves according to different mounts. In
the curve that corresponds to the direct
mounting on the surface, one observes that
the accelerometer could be used to
measure frequencies of up to 10,000 Hz
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without any resonance problems in the

sensor. In the case of the magnetic base mount, if
and when the measuring spot is free of
Quick connection mounting is obtained by grease and perfectly clean, one can record
providing the measuring equipment with a frequencies in the order of 6,000 Hz.
threaded base fitted with cement or a
screw. On the other hand, the The choice will depend on the user and his
accelerometer will have a special connector finances.
with internal threads. When the sensor is
fixed to the base, a good coupling is
formed. The connection is managed quickly
and the frequency of 8,000 Hz is obtained.

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Table 1. Accelerometer mounting types

FREQUENCY RESPONSE CURVES

1. Direct to the surface
mount

FREQUENCY IN HZ

2. Quick connector
mount

FREQUENCY IN HZ

3. Magnetic-base mount

FREQUENCY IN HZ

4. Threaded tracing point

FREQUENCY IN HZ

7.3 Selection of measurement points on

the equipment

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The selection of measurement points on the
equipment will greatly depend on the
sensor's mount and on the accessibility of
the measurement points.
In chapter 5, we presented different
formats for the registration of the acquired
information, and using the previously
presented points it is recommended to
collect the most possible information from
the equipment which means taking vibration
data in horizontal, vertical and axial
directions at each measurement point.
This information will be valuable for the
problem diagnostic when the vibration
levels go beyond the limits established in
Table III, Chapter 6.
As a general norm, the measurement points
should be located as close as possible to the
equipment supports in order to register a
reliable information at each point.
When the measurement points are far from
the supports, there is a risk of getting a
weak signal which could create a situation
in which the alarm levels are never
reached.
However, at times it will be impossible to
reach the points closest to the supports. In
these situations, it is recommended to
observe attentively the spectra obtained in
search for any frequency generated by
bearing or gear failures.
The readings of the horizontal and vertical
directions will be taken following a radial
pattern. It is not recommended to take
these readings in a tangential manner, for
example, on top of a motor or pump.
We have this situation because the
tangential readings are greater than radial
readings. This difference is caused by the
equipment' movements and possible bending
(deviations).
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The tangential readings will only cause the
capping of alarm levels when the equipment
is operating in good condition; thus, causing
the analyst's time loss and confusion.
In case of the disc placement as magnet
bases or threaded discs for the quick
connectors, it is recommended to identify
them with a letter to avoid confusion among
the personnel that collects data.
As a general rule, it is recommended to use
the letters H, V and A for the horizontal,
vertical and axial readings respectively.
In addition, it is recommended to place
protective covers on each disc to prevent a
grease or dust collection. This procedure
will shorten the data collection time
because there will be no need to constantly
clean the equipment. These covers can be
plastic.
In figure 2, there is a typical arrangement
of the strengthening plate measurement
points.
Figure 2. Measurement points.
The markings for horizontal, vertical and
axial axles will be respectively H, V, and A.
In the case of the vertically installed
equipment, both radial readings will be in
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the horizontal position and for this reason it
is recommended to use different
abbreviations for the identification of the
measurement points.
Cardinal axis could be used for the
identification of the process route; for
example, a radial reading for a vertical
pump is usually taken in the direction of the
tube's exit and the other at 90°.
The reading in the direction of the fluid
movement could be identified with the
letter F and the one at 90° from it with the
letter P, showing in such a way that it is a
perpendicular reading in the direction of
the fluid's movement.
7.4 Efficient tracing of monitoring routes
In most predictive maintenance software,
the monitoring routes could be configured
in accordance with the user's needs, which
is the case of the CSI Master Trend System.
Normally the data collecting personnel
establish the monitoring routes according to
the physical distribution of the equipment
in order to optimize the data recording
time.
In this way the information is recorded in
one or more plant sections and it is sent to
the computer.
However, in some plants the time element
has been sacrificed in a way that seems to
be attractive: recording the information by
"family" groups (equipment with common
characteristics).
This recording method requires the
monitoring routes to be organized according
to equipment's characteristics. For
example: pumps, ventilators, gearboxes,
blowers, etc.
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The primary objective of these routes is to
group equipment according to its
characteristics and thus facilitate the
analytical process. Thanks to this method,
the spectra analysis will be easier because
the analyst will be focused on the specific
type of equipment; and he could use
methods like spectra comparison, as well as
the specialized and comparative equipment
of the same type.
Either of the two ways for planning
monitoring routes is correct; however, the
selection of the adequate method will
depend on the plant size and the existence
of common type equipment.
If the distance between machines of the
same type is great, it is preferable to use
topographic routes.
In either of the two cases, it is important to
take into account the following suggestions:
1. In the initial stages of the system's
implementation, it will be necessary to take
spectra of high resolution in all
measurement points (at least 1600 lines)
with the purpose of obtaining the initial
equipment reference. Record the wave
spectra and form.
2. Adding additional measurement points,
as is the case with electric or gear
frequency measurement points, take into
account that these points should be
selected immediately after the usual
measurements.
For example, for the electric frequency
readings, the measurement point with this
range of frequency should be defined after
the point with the normal bearing frequency
rage.
The previous recommendation is offered
with the intention of taking advantage of
the sensor's connection to the base and the
opportunity to take two readings from the
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same measurement point without taking it
off and putting it on again.
3. The later readings could have 400 or 800
resolution lines to avoid the saturation of
the computer's memory; the exception to
this principle could be the points that
require a higher resolution like electric
frequency points.
4. Do not saturate the data collector with
too many routes because it is often
necessary to take additional readings with
high resolution when potentially chronic
problems are detected in the work area.
The unnecessary data diminishes the
available computer memory, and it prevents
the recording of the rest of the equipment's
measuring points.
It is important to unload the information
continuously in order to be always capable
of storing new spectra information.
5. Preferably, record the vibration wave
shape only when the alarm levels were
triggered in the collector. The analysis of
the wave shape will be an important tool
when problems are presented in bearings
and gears, and in many different kinds of
problems.
In the software, it will be possible to select
the time for the wave shape recording and
the spectrum depending on the alarms going
off as it was previously described.
It is not necessary to always store the wave
shapes in order not to saturate the
computer's hard disk, unless it has a great
capacity.
In the equipment that is not critical for the
process, it is recommended to record the
spectrum and the wave shape only when the
established alarms are triggered.
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7.5 Definition of monitoring priorities
After establishing a vibration-monitoring
program, it will be necessary to define the
schedule for the data collection from the
equipment.
The monitoring periods will vary according
to the type of the equipment that is
monitored and its priority for the
production.
According to general practice, a 30-day
period is considered to be adequate for
most industrial equipment. However, it will
be necessary to diminish this period when
the alarm vibration levels are detected in
critical machines for the process.
The previous is applicable to equipment
that has spinning frequencies higher than
600 CPM. In machines with spinning
frequencies lower than 600 CPM, it is
recommended to apply 60 day monitoring
periods.
This is due to the fact that they will present
minor problems in comparison with the
equipment with major velocity. However,
in case of a reading abnormality, it is
recommended to diminish the monitoring
frequency.
On the other hand, in the equipment that
has not presented any problems in several
readings, it is recommended to extend the
monitoring period, for example, from 30 to
60 days.
In addition, it is important to mention that
in order to have an adequate Predictive
Maintenance System, it will be necessary to
have sufficient data for the effective
calculations that are performed by
software. When there is a meager amount
of data in the system, the prognostics will
not be as precise as when there is a
complete record.
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Consequently, it is not recommended to

have monitoring sessions scheduled for
more than 60 days apart because the
quantity of accumulated data will be low
and the analyst will not be able to predict
adequately the behavior of the equipment.

If on the contrary, the monitoring sessions

are too frequent, for example every 15
days, the collection task will be wearisome
and it is very probable that the computer
hard disk gets saturated prematurely.

Thus, it will be necessary to define

monitoring periods in accordance with the
plant machines, paying close attention to
the equipment that is very critical for the
process.

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CHAPTER 8
Monitoring procedure for the low
spinning velocity equipment
(lower than 600 CPM)
8.1 Introduction
A lot of specialists have considerable
experience in the area, but there is
insufficient or no work experience with the
equipment with low spinning frequency in
the range of 1.5 to 300 rpm. In some cases,
even the most necessary type of the
equipment used to make the precision
monitoring sessions is unknown.
Due to this lack of knowledge, when
initiating the Predictive Maintenance
System, it is common that the low spinning
velocity equipment remains excluded from
the program, even though these can be
critical for the process.
Generally, the equipment of low spinning
frequency has an axle diameter from 4 to 20
inches or more, and they are typically large
in size. Consequently, when the bearing
failures start in these units, the resulting
vibration in the bearing box will be very
low.
Consequently, it is possible that some
potentially serious problems remain
unheeded. For example, in units spinning
at velocities lower than 20 rpm, it will be
almost impossible to detect a bearing
failure using a spectral analysis; however, it
could be detected through the wave's shape
analysis (time domain).
Additionally, the criteria for the severity of
normal vibrations, as seen in Table I of
chapter 6, will not apply to equipment with
low spinning velocity due to the great
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amplitude difference in the area of low
frequency.
In this chapter, we shall explain the general
procedures for the correct vibration level
measuring of low spinning frequency, and
the recommended alarm levels for this
equipment will be seen.
8.2 Selection of the optimal parameter
for the low frequency measurements
(acceleration, velocity and
movement)
In accordance with Figure I shown in
chapter 6, pages 63, we can summarize that
every measurement unit, movement,
velocity and acceleration have their specific
applications depending on the frequency
range that one wished to measure.
Referring to this chapter's subject matter,
when it is necessary to obtain information in
very low frequencies, it is recommended to
use movement as a measurement
parameter.
Its usage will be focused on detecting the
failures like unbalance, lack of alignment or
eccentricity in the axle or other
components that spin at a low velocity,
inferior to 600 cpm.
However, the movement will have very
little sensibility for the events that occur at
frequencies higher than 600 cpm, especially
when there are multiple harmonic waves
that could be generated, for example, by a
loose bearing in its box.
For the frequencies that are ranging from
600 to 60,000 cpm, it is recommended to
use the velocity as the optimal
measurement parameter. Even though the
equipment spins, for example, at 60 cpm, it
is very probable that the bearing failure
frequency of this axle is above 600 cpm.
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Consequently, It is recommended to use the
movement as an optimal parameter to
measure equipment's unbalance and lack of
alignment; and to use velocity to evaluate
the bearing condition.
In figures 8.1 and 8.2, the spectra of the
bearing on the coupler's side of an induced
draft ventilator that spins at 250 rpm
approximately are presented. As it can be
observed, the movement spectra do not
provide any information about the bearing
condition, we can only see that the
vibration at spinning frequency is low.
The velocity spectrum presents in the
clearest manner a series of corresponding
failing frequencies of this roller, which is
damaged because of the inadequate
lubrication.
The acceleration will only be used when the
frequencies go beyond 300,000 cpm, which
indicates that this parameter will not be
useful for low frequencies.
As one of the main functions of the
predictive maintenance system is focused
on the vibration level tendencies, especially
on the bearing vibration tendencies, in this
chapter, we shall see that the best
parameter for the analysis of the
equipment, that spins at frequencies higher
than 60 rpm, will be the vibration velocity.
8.3 Required equipment for low
frequency analysis
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Two important factors should be taken into
account at the time of taking measurements
for the equipment of low spinning
frequency.
The first one refers to integration processes
that take place in the moment the signal
that comes from the accelerometer, is
integrated into the velocity or movement
data. Today, most of the available
equipment is supplied with special filters to
avoid the noise at low frequencies.
Consequently, it will be necessary to pay
close attention when selecting the
instruments that will be used for these
measurements. The main objective of
these readings is to consistently provide
reliable information.
When the readings are not consistent, the
equipment's behavior will be unpredictable
if we base our findings on the accumulated
vibration level tendencies.
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SPINNING FREQUENCY 1X RPM (249.2 cpm)

SPECTRUM OBTAINED IN MOVEMENT

harmonic wave activities or bearing

frequency failure are not observed

Table 8.1 Spectrum obtained in movement (mils peak-peak)

SPINNING FREQUENCY 1X RPM (249.2 cpm)

SPECTRUM OBTAINED IN VELOCITY

ventilator bearing failure frequency

Table 8.2 Spectrum obtained in velocity (in./sec. peak)

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In conclusion, as the equipment is a very
important factor, it is recommended to use
integrated analog spectra with a narrow
band width, for example: 20,000 cpm for
spinning frequencies of 60 rpm and a high
resolution equal or higher than 1600 lines.
The transducer is the second important
factor for the low frequency measurement
that should be used to obtain reliable and
quality readings for analysis.
Most of the accelerometers used in the
industry for its preventive maintenance
systems have a measuring range of 120 cpm
and higher.
Actually, there are high frequency
accelerometers that measure from 120 cpm
to 600,000 cpm.
Normally, these accelerometers are used to
detect problems related to bearings, gears
and the first harmonic wave spinning
frequencies in which one might observe
problems related to unbalance, lack of
alignment, etc.
However, this type of accelerometers could
not be used to measure frequencies that go
beyond its minimal level. For such purpose,
low frequency accelerometers have been
developed, thanks to them reliable data
could be obtained in the range of low
frequencies, but it will have limitations with
respect to high frequencies.
The typical operation range of these sensors
is from 6 to 60,000 cpm, and its weight
varies from 135 to 1,000 grams. They are
larger than normal accelerometers.
Its resonance frequencies initiate in the
range of 390,000 cpm and its sensitivity
varies from 500 to 10,000 mV/g.
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Some low frequency accelerometer that
could be found on the market are:
- Wilcoxon Research mod. 793L (c)
- Wilcoxon Research mod. 793L (c)
- CSI mod. 320L (c)
- PCB mod. 326A02 (s)
- PCB mod. 326A03 (s)
- B & K mod. 8318 (s)
Each one of them has its characteristic
properties with respect to frequency and
sensitivity. All of them could be used for
low frequency measurements.
Some of them are compression type (c) and
others cut type (s). When using a
compression type accelerometer, it is
recommended to wait for at least 3 minutes
so that the sensor temperature can be
stabilized.
In the cut type accelerometers, it will not
be necessary to wait for the temperature to
stabilize. Actually, they are most
recommended for low frequency
measurements.
In addition, it is recommended that the
sensors have at least a sensitivity of 500
mV/g, and preferably 1 V/g.
The preferred mount for this type of low
frequency accelerometers is a fast
connector or a magnetic base.
However, one will obtain better results
when screwing the measuring equipment to
the surface in question.
It is very important to mention that during
the low spinning frequency reading, the
total time of measurement should be at
least from 2 to 3 minutes due to the low
frequency range and high resolution lines.
Due to the previously stated, one should try
not to move the accelerometer's cable and
not to place it near motors or transformers
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to avoid electromagnetic interference
(EMI). This interference would cause
erroneous readings in the spectrum.
8.4 Bearing evaluation in the equipment
with low spinning velocity.
The rollers or bearings could be evaluated
satisfactorily even in the equipment with as
low spinning velocity as 1.5 rpm. However,
one should take into account the equipment
as well as the mere sensor, with respect to
what was seen in the previous segment.
In addition, one needs to take into account
the spinning frequency of 1X RPM as well as
the bearing failure frequency; low values
will be recorded for large equipment and
low spinning frequency. Consequently, it
will be very important that the sensor is
located in the bearings' charge zone in order
to detect its problems.
This will be of considerable importance
especially when the ball rollers are large
because the internal tolerance among balls
and tracks allow that in some bearing
sections the balls have no contact with
external tracks, especially at 180° from the
charge zone.
If the sensor is placed exactly in this area,
it will be impossible to obtain spectra with
bearing failure frequency information.
Consequently, it will be necessary for the
sensor to be positioned in the charge zone,
either in radial or axial direction.
The Table A-12 of the Nexus A shows the
four classical stages that 80% of bearings
undergo. It is important to emphasize that
during the second stage of bearing failure,
their natural frequencies are excited. This
occurs when the wearing has progressed to
the point of causing shocks within the
bearing components.
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It is important to note that the components'
natural frequencies will remain constant,
independently of the bearing spinning
frequency. The frequency difference is not
observed between a spinning velocity of
10,000 RPM and 100 RPM.
Of course, the only unique difference that
will exist is the quantity of energy
generated by the impacts, the axle that
spins at 10,000 RPM has greater energy
peaks than the axle that spins at 100 RPM.
Consequently, the vibration amplitude in
the natural frequency zone will be much
greater than in the equipment of high
spinning velocity.
The normal frequency range established
through the bearing observation in the
equipment is 50 to 60 times the spinning
frequency. However, for the equipment of
low velocity, for example equipment that
spins at 100 CPM, the maximum checking
frequency will be 6,000 CPM.
In this frequency range, we can observe the
final stages of the bearings' damage, but the
initial stages are not presented when their
natural frequency is excited because the
natural bearing frequencies are found in the
range of 30,000 to 120,000 CPM.
Due to the previous statement, it will be
necessary to define additional checking
points in key areas of the equipment with a
frequency range of at least 150,000 CPM,
with the purpose of observing the initial
damage stages.
As the last point, it is important to capture
and accumulate the wave vibration shape
that was obtained in acceleration,
especially in equipment with spinning
velocity smaller than 60 CPM. It will be
possible to observe the impacts caused
when the ball and rollers enter in contact
with the damaged part, either on the
internal or external track.
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The reciprocal time period between the This value will be used to define all spectral
impacts will be the BPFO, BPFI and BSF bands in accordance with the procedure
frequencies, depending on the location of previously seen in chapter 6.
the damaged part.

8.5 Specifications for the alarm levels in

the spectral band for the low spinning
velocity equipment

The narrow bands that were defined in

Table III, chapter 6, will not be applicable
to the analysis of low spinning velocity
equipment because the vibration velocity
looses sensitivity when the frequencies are
lower than 600 CPM.

However, the existing relation between the

movement and velocity at frequencies lower
than 600 CPM is linear. Consequently, the
following empirical formula can be used to
define the spectral band alarms following
the chapter 6 procedures:

Alarm BF = (Alarm FM) (Fi/600)

in which:

Alarm BF = Alarm level for low frequency (Fi)

which is calculated in in./sec.

Alarm FM = Alarm lever for moderate

frequencies obtained from the Table II,
chapter 6, in in./sec.

Fi = Frequencies on which one wishes to set

the alarm levels in CPM.

For example, in the table II, chapter 6, for a

general-purpose horizontal pump, we have
an alarm level of moderate frequency,
0.3000 in./sec. Supposing that the pump
spins at 100 CPM, the alarm level would be
at:

Alarm = (0.3000) (100/600)

BF
= 0.050 in. per sec.

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CHAPTER 9
Application procedures of the
demodulation techniques
9.1 Introduction
One of the most valuable tools for the
premature detection of failures in gears and
bearings is the demodulation technique. In
this chapter, we shall describe a
demodulation technique as well as its
application using a CSI Demodulator model
750 in conjunction with an Analyzer 2115.
Recommendations for an adequate use will
be offered and a practical example will be
presented.
9.2 Demodulation basic principles
In the initial failure stages of bearings or
gears, as well as in friction and lack of
lubrication problems, vibration levels at
high frequencies will be generated.
Thus, it will be very difficult to determine
which one of the previous causes is creating
these vibration levels at very high
frequency; especially when they are
combined in one equipment, gear and
bearing, as well as in a mechanical seal.
Especially for the bearings, the vibration
level value was used in the area of high
frequency (Spike Energy or HFD) to
determine their replacement date.
However, in some experiments realized, no
failure was found on the bearing track.
It was discovered in an investigation that in
the premature bearing damage, the damage
itself originates in an area between 4 and 6
thousandths of an inch on the inside part of
the bearing tracks.
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The passage of balls or rollers through this
failure area excites natural frequencies of
the transducer or in the region of an
ultrasonic frequency. Therefore, the ball's
passing frequency through the tracks will
modulate the natural frequencies that will
be excited.
The demodulation technique will work in
these areas of high frequencies using the
wave shape that comes from the transducer
and that could contain the bearing's
harmonic wave frequencies, as well as the
natural frequencies of the transducer or
components of the equipment's structure.
The demodulation process consists of the
rectification of the complete wave from
which it determines the existent spacing of
the excitable frequencies (bearings and
gear). The wave shape obtained through
this process is submitted to a low passage
filter with the purpose of eliminating the
resonant or "transported" frequency.
Finishing this process, a demodulated
spectrum could be obtained which will
contain only the frequencies that excite
very high frequencies.
These frequencies, also called "carriers",
could correspond also to bearing failure or
to the spinning frequency of a specific gear
that is causing problems in a gearbox.
This way, the analyst could adequately
monitor the initial stages of bearing or gear
failures of the most critical plant
equipment.
In the case of bearings, it is important to
specify that insufficient lubrication will also
show on the demodulated spectrum the
bearing failure frequency. It is
recommended to lubricate the part in
question and take another demodulated
spectrum after the lubrication.
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The equipment should be checked 24 hours
after the lubrication to observe whether the
demodulated spectrum still presents bearing
failure frequency.
In case the bearing failure frequencies
reappear, one can conclude that the
bearing is in the initial failure stage,
predicting an additional 20% of its "life
expectancy".
As the demodulation technique is applied to
vibration levels of very high frequency, it
will be very important to select an
appropriate accelerometer for the
equipment type as well as its mount in
accordance with the information presented
in chapter 7.
In the specific case of CSI Master Trend
software, it is possible to determine
measurement points with demodulation,
when using one of the seven filters that the
Demodulator 750 has. In this way, one can
use demodulated spectra to detect
premature bearing and gear failures.
9.3 Functions of the CSI Demodulator 750
The Demodulator/Pre-processor 750 is the
Analyzer 2115 accessory and it is adhered to
its back. The Analyzer provides energy and
it can remain connected even when it is not
in use.
The Demodulator/Processor 750 offers three
main functions:
- It permits the use of a low noise
preamplifier to improve the function of the
Analyzer 2115 in case of very weak entrance
amplitude.
- It permits the selection and use of any of
the six filters (or none).
- It permits the use of demodulating circuit
as an entrance signal processor for the
analyzer.
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The functional diagram of the Demodulator
750 is shown on the Table 9.1. On this
diagram, the following functions will be
explained:
Preamplifier
The first step in the Processor 750 is the
preamplifier, which has a purpose of
incrementing the signal's entrance level of
low amplitude to the point of boosting the
signal to the level that can be processed in
the following stages eliminating the
problems of the coefficient signal/noise.
In this stage the amplification can be
configured in such a way that it becomes
automatically adjustable or to chose a value
of 0.2, 1, 10 or 50.
The manual selection of amplification can
be used only in the mode "Analyze" of the
Analyzer 2115. For the effects of the signal
transmission to the demodulator, it is
recommended to use the Auto range mode.
Filter options
The following stage in the use of the
preprocessor is the selection of filters, one
of the eight filters can be chosen. Five of
these filters are "high pass", two are "band
pass" and one permits all the frequency
signals or "bypass".
The appropriate filter selection requires the
knowledge about the entering signal that
will be analyzed.
The filters of high pass avoid the level
reduction of the transported signal whose
frequencies are above the specific filter and
represent an important attenuation of the
signal frequencies that are bellow the
cutting limit.
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The demodulator has 4 general-purpose stage, it presents useful frequencies as are

passing filters with frequencies of 500,
1000, 2000 and 5000 Hz. In order to better
illustrate the use of these filters, let's
suppose that the signal transmitted for
analysis is in the frequency range from 2500
to 4000 Hz (this can be realistic for the
beginning of the bearing failure) and the
spectrum shows in addition a gear
frequency in the range from 400 to 500 Hz
that comes from the gear frequency of this
equipment.
For this particular case, the appropriate
filter should be selected from the 1000 and
2000 Hz pass filters.
This way, the spectrum signal that comes
from the gear will be attenuated, leaving
only the bearing signal.
An additional, fifth, high-pass filter with the
frequency limit of 100 Hz will be added in
order to detect no uniform air gaps in
induction motors. This filter attenuates the
fundamental frequency of the electric line
the pole passage frequencies that function
as lateral bands in case of eccentricities in
the air gap and even in situations of loose
rotor rods. (See "Electric problems" in
Nexus A)
The example that is presented in this
chapter is about loose rods.
In addition, this filter of 100 Hz can be used
for general purposes in the applications that
require it, we recommend it in the case of
low spinning velocity reducer in which one
could observe the gear frequencies.
The passing filters of the existing bands will
be used for the electric frequency analysis
with the purpose of eliminating all the
signals that are not included in the selected
band. There are filters from 50 to 60 Hz
depending on the electric frequency of the
line.
These filters should be used only when the
induction motor current is measured.

ENTRANCE

PREAMPLIFICATOR FILTER
1 OF 7

AMPLIFICATOR:

DEMULATOR FILTER

EXIT

Table 9.1 Fundamental diagram of the CSI Demodulator/Processor model 750.

and, in coordination with the demodulation Demodulation stage
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The fourth and last stage of the Processor
750 is demodulation. The demodulator
accepts at the entrance the signal known as
"transported".
The exit signal of the demodulator will be
known as "base band". This base band signal
will contain the necessary information for
the analyst because in this base band will
be included signals known as "carriers" and
that could be the bearing failure
frequencies, the spinning frequency of a
damaged gear, or the lateral bands
corresponding to the pole passing frequency
for electric problems.
The minimum frequency of the base band is
normally constant at zero or very close to
zero, while the maximum frequency is
known as Fmax.
It will be very important to set permanently
Fmax of the base band mostly at one half of
the expected frequency of the transported
signal. In other words, if one estimates that
the transported signal has a frequency of
120,000 CPM, the Fmax of the base band
should not be greater than 60,000 CPM.
The previous is due to the fact that the base
band Fmax is greater than 50% of the
transported signal frequency; it is possible
that the lateral bands of the transported
signal overlap with the higher portion of the
base band frequency range distorting the
signal that might confuse the analyst.
It is important to remember that the
transporting or modulating frequencies
brought to the spectrum appear as lateral
bands of the transported frequency.
Consequently, these lateral bands should be
included in the high passing filter of 400 Hz
in order to eliminate the residual
components of the transported frequency.
If these components are not eliminated they
will impact the spectral base band result.
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As a general rule, when the demodulation
function is in use, the analyzer's Fmax
should not exceed 400 Hz or half of the
transported signal's frequency, using the
lower value.
9.4 Example of Demodulator 750's use
We shall present a typical case of the
Demodulator 750's use for the loose rotor
rod detection in induction motors.
The case is based on the ventilator motor
that is attached directly to an axle. The
power of the motor is 75 HP and it is
attached to vibration insulators. This motor
has been experiencing continuous changes
in bearings and it was also rewound in two
occasions during the last two years.
In addition, a rhythmic noise could be heard
in the motor and the 1X RPM vibration
amplitude would rise and dip en par with
the noise rhythm.
This type of rhythmic vibration could be
coming from another machine located in
close parameters which is spinning at a
frequency very closely related to this motor
(see page A-20 of Nexus A).
However, in this case the motor in question
is isolated and distant from the rest of the
ventilators of the group that belong to the
same production line.
Another possible cause of rhythmic
vibrations at the spinning frequency is the
existence of loose or cracked rods in the
motor's rotor. The lateral bands that are in
the spinning frequency and in their
harmonic waves produce this rhythmic
vibration, and their distance is equivalent
to the passing frequency of the poles, or Fp
(See A-17 and A-18 of Nexus A).
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It was proceeded to acquire a spectrum in

the horizontal direction on the charge side
of the motor with a frequency range of
12,000 CPM and a maximum resolution of
3,200 lines which is shown on Table 9-2.
In this no demodulated spectrum, it is
observed that the first 3 harmonic spinning
frequency waves (1x, 2x and 3X RPM) show
acceptable vibration levels. However, even
though the amplitudes are very low, the
lateral bands of low separation frequency
are piled up in each one of the bands.
The lateral bands in the first spinning
frequency harmonic waves indicates loose
or cracked rods in the rotors of induction
motors, if and when these lateral bands are
spaced according to the pole passing
frequency or Fp.
Fmax was set at 3,000 CPM and a high pass
filter of 100 Hz was used in order to cover
all the spinning harmonic wave frequencies.
The demodulated spectrum is presented on
the Table 9.3.
In this spectrum, one observes pole passing
frequency Fp and its harmonic waves. From
the information related to this spectrum, it
was concluded that this motor rotor had one
or more rotor rods loose or cracked.
Additionally, a spectrum analysis of this
motor's current was done, and it was
corroborated that there were loose rods.
Based on this diagnostic, it was decided to
replace this motor because it was
impractical to repair it.

The pole passing frequency Fp is defined in 9.5 Conclusions

the following manner:
Fp = Np * Fs
where:
Fp = pole passing frequency
Np = number of stator poles
Fs = Slipping frequency
When it is appropriately used, the
Formula 9.1 demodulation technique offers valuable
information that could not be obtained from
a normal spectrum, especially when it is a
question of initial failures of bearings and
gears.

The slipping frequency Fs is calculated

subtracting real spinning frequency from
synchronic spinning frequency. For this
motor, the spinning synchronous frequency
is approximately 3598 RPM (the line's
electric frequency was 59.96 Hz), and the
real spinning frequency is approximately
3573 RPM.

Because this motor is made of two poles,

the passing pole frequency, as suggested in
Formula 9.1, will be 50 CPM. To obtain the
modulation frequency, also called lateral
bands, in the spectrum without
demodulation of Figure 9.2, an additional
spectrum was taken on the same place using
Demodulator 750.
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For the adequate application of this It is important to remember that the

technique, it will be necessary to minimum frequency of a demodulated
initially know the relevant frequencies spectrum could be zero that is impossible
of the signals known as "transported", for normal spectra, in which the first three
knowing them it will be possible to set resolution lines are eliminated because of
correctly the passage filters, as well as to the low frequency noise created by the
chose the band and the Fmax which should integration process.
be defined.

VENTILATOR NUMBER 3

Spinning Frequency

2X electric freq.

3X spinning
freq. with
lateral bands

Table 9.2 Spectrum with motor demodulator

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VENTILATOR NUMBER 3

pole passing harmonic wave

frequency

DEMODULATED SPECTRUM

High passage filter of 100 Hz

Table 9.3 Demodulated motor spectrum at 100 Hz

Comment [MPC1]:

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CHAPTER 10
Criteria for measuring results -
Maintenance indicators
10.1 Introduction
As it was mentioned in chapter 1, the
fundamental objectives in the
implementation of the Predictive-
Preventive Maintenance System are the
control of maintenance costs and the
efficiency increase in the productive
process.
In order for the Predictive-Preventive
Maintenance program to be successful, it
needs to quantify the obtained results. The
objective can be reached with the use of
some base indicators of the system's
function.
In this chapter, we shall see the subject of
maintenance indicators that were used to
quantify the implementation benefits of the
Predictive Maintenance System.
Most of the indicators were mentioned and
a detailed description will be made of those
that are most recommended and generally
used in industry.
The calculation of these indicators could be
automatically done in the plants, which
have a computerized maintenance
administration system. However, in the
plants that do not have such systems, the
effort made in obtaining the information
and calculating the indicators will be
rewarded when the benefits obtained are
presented.
On the other hand, it will be necessary to
have the initial indicators data when
starting to implement the system, in order
to have the starting and comparison points
for the future work.
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In some plants, this will not be a major
problem because they count with most of
the information. For the plants that are
only introducing the system of indicators, it
is recommended to make an additional
effort before initiating the predictive
maintenance system.
10.2 Maintenance Indicators
For the recording of the obtained benefits
with the implementation and operation of
the Predictive Maintenance System, it will
be necessary to use the following
Maintenance Indicators:
- Percentage of the "out of service" time for
maintenance reasons, as a total time
function (availability).
- Emergency hours vs. total hours of labor.
- Maintenance cost per tone of product.
- Number of problems detected with
vibration analysis per month.
- A vibration average in relation to the
global value for the whole plant or the
production line.
- The percentage of the problems resolved
vs. detected problems with vibration
analysis (percentage of corrective action).
The first six indicators are the most
important ones for the continuation of the
Predictive-Preventive Maintenance System.
However, we are going to present some
others that could be used:
- Total departmental maintenance cost per
month.
- Number of corrections made thanks to the
Predictive-Preventive Maintenance System
per month.
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- Tones of the produced product per
month.
- Total of the defective units or monthly
loss.
- Percentage of waste or defective parts vs.
total production
- Number of incidents beyond the tolerance
level per month.
- Extra time as a percentage of total hours
of labor.
- Percentage of time that the equipment
was used vs. the time of its availability.
- Number of problems found by the
Predictive-Preventive Maintenance System.
- Percentage of the equipment included in
the Predictive Maintenance.
- Consumption and cost of the electric
energy per month.
- Monthly cost of replacement parts.
- Monthly cost of the inventory parts.
- Number of inventory parts eliminated from
the shop per month due to the maintenance
improvements.
- Average time between repairs or
replacements of the equipment.
- Number of detected problems thanks to
the vibration analysis that have not been
resolved per month.
- Number of problems detected thanks to
the vibration analysis that have not been
resolved in more than 3 months.
Even though there are many indicators that
deserve attention, a procedure can be
elaborated to record the necessary
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information in order to have it constantly
available.
In this aspect, the work done by the
Maintenance Director will be finished. As
the leader of the Predictive Maintenance
Group, the director should establish
communication ties with the departments
that have the information necessary for the
calculation of the indicators.
The Maintenance Predictive Group should
process this information in order to
elaborate the monthly report of the
Predictive-Preventive Maintenance System,
showing the progress and benefits of the
program.
It is recommended to make tendency graphs
with each one of the indicators to show the
progress of the Predictive Maintenance
System. This report should be circulated at
the plant and directed to the General
Management.
It is recommended to send a copy to the
Technical Department for the evaluation of
each plant and be able to determine which
plant has obtained the best results.
While waiting to establish communication
channels in order to obtain all the necessary
information for the recording of the
indicators, it is recommended to start with
the Table 1 indicators.
The 6 indicators from Table I could be used
as an initial step in the program's
evaluation. In most of the plants, the
sufficient information is available to
elaborate these indicators.
10.3 Conclusions
The elaboration and continued analysis of
the maintenance indicators will be very
important for the Predictive-Preventive
Maintenance System. The reason is very
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simple; they are the "measurement

instruments" for the system's condition.

The same way we evaluate the conditions of

the specific machines, we should evaluate
the progress and benefits of the System.

Special attention should be paid to the

reports of potential benefits gained by
corrections; in other words, report the cost
of the repair done on time with the cost of
a catastrophic failure if the failure had not
been prevented.

The reports of the obtained results, which

will be discussed in chapter 11, will be very
important in the initial implementation of
the system. This type of specific situation
reports will give a boost to the system and
gain support and confidence from the rest
or the plant's staff, including of course the
General Management.

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TABLE I. CALCULATION OF THE MOST IMPORTANT MAINTENANCE INDICATORS

MAINTENANCE INDICATORS OBJECTIVES

1. AVAILABILITY
Stoppage time due to maintenance 90% first year
Availability = 1 - ---------------------------------------------------------------------
-- 96% second year
Total time during production time

2. MAINTENANCE UNIT COST PER TONE PRODUCED

Total maintenance cost during the period lowering tendency

Cost/Unit = --------------------------------------------------------------------
Number of tones produced during the period

3. PERCENTAGE OF MAINTENANCE EXTRA TIME

less than 10%
Extra time total during the period during the first year
Extra T. % = -------------------------------------------------------------------------
Total of the normal working time during the period less than 5% during
the second year
4. PERCENTAGE OF HOURS SPENT IN CORRECTIVE MAINTENANCE

Total hours of labor in emergencies less than 20%

% of corrective during the first year
maintenance labor = -----------------------------------------------------------------
- less than 10%
Total hours of labor in maintenance during the second
year
Number of emergency interventions
% of corrective labor = ---------------------------------------------------------------
---
Total number of jobs done

5. PERCENTAGE OF THE EQUIPMENT INCLUDED IN THE PREDICTIVE MAINTENAN

More than 75% during
Number of machines included in the program first semester
% of the achievement = -----------------------------------------------------------
Number of potential machines for Predictive Maintenance 100% at the end of
the first year

6. PERCENTAGE OF THE REALIZED CORRECTIONS

More than 50% during
Number of failures detected by and corrected first semester
% of implementation = ----------------------------------------------------------------
Total number of failures detected by Predictive M 100% at the end of
the first year
Note: The failure is considered to be corrected when its vibration levels are
within the permissible limits

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CHAPTER 11 d. When there is a need to analyze an

equipment that for some reason was not
included in the system.
Writing reports
These reports will be submitted to the
director of the area in which the equipment
11.1 Introduction
is located, and if such person is not
available, it should be presented to the
One of the PPM personnel's most tedious
Maintenance Director of the plant.
obligations is writing reports. Essentially,
there are two types of reports: a technical
The primary objective of this report will be
report which contains the analysis results
to describe to the plant maintenance
and recommendations for problem
personnel the exact vibration condition of
resolutions; and the second report is for the
the equipment.
management in which is included the
benefit accretion gained by problem
For this reason, one should include in the
resolutions. The latter should also include a
report the following section in accord with
brief diagnostic of the situation and the
Table 11.1.
work accomplished.
SCHEMATIC DIAGRAM
In this chapter, we shall see the importance
that both reports have in the Predictive-
In this section, one should elaborate a
Preventive Maintenance System, and the
schematic diagram of the equipment,
recommended format shall be elaborated in
showing its measurement points. Today,
order to have the optimal impact on the
there is a large number of computer
person who will receive it.
packages for a simple elaboration of these
diagrams and their interface with word
processors.
11.2 Vibration Analysis report
The report from Figure 11.1 was elaborated
The vibration analysis reports should be
with a package called VISIO that runs on
elaborated when the following situations
Windows. Other kinds of packages that
occur:
could be used are: CorelDraw 4.0, Word for
Windows, etc.
a. When equipment has high vibration
levels, which were presented during the
EQUIPMENT IDENTIFICATION
first monitoring session at the initiation of
the system.
In this section, the equipment information
should be included: its name and
b. When equipment presents abrupt
identification, section to which it belongs,
changes in vibration levels which were
date when the data were taken and the
measured in two consecutive monitoring
date when the analysis report was
sessions.
elaborated. The name and the signature of
the analyst should be included also.
c. When the vibration level tendency has
incremented in such a way that it requires
NUMBER OF THE WORK ORDER
an action in the next 30 days.
The number of the work order will be
important in order to follow up with the
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work that was done in this equipment. In
case there is an Administrative Maintenance
System interface at the plant, this number
could be assigned directly from the PPM.
This will depend on the system that was
implemented at each plant.
VIBRATION LEVELS
In this report, five levels of vibration that
show the operational conditions of the
equipment will be defined. Depending on
the actual equipment condition, one should
select one of the five severity vibration
criteria.
This way, the person who receives the
equipment will know in which condition the
equipment is operating.
REPAIR PRIORITY
Depending on the vibration severity and the
equipment priority as far as the critical
equipment is concerned, one should
determine the action plan and the follow
up, either repairing or monitoring at short
intervals.
PROBLEM DESCRIPTION
In this section, one should include a brief
explanation of the problem, mentioning the
possible causes of the vibration and in
which measurement points the problem was
discovered.
The potential dangers and losses that could
be suffered in case no action is taken in the
time frame established by the analyst
should also be included in this section.
RECOMMENDATIONS
In this section, one should include the steps
that should be followed in order to resolve
the vibration problem. These steps should
preferably be listed chronologically or
following a procedure that was previously
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mentioned for the problem correction in a
specific machine.
It will be very important to explain in the
clearest possible manner the
recommendations because thanks to them
one will obtain the solution to the problem.
As the last point suggestion, one should
annex in the right lower corner the most
important spectra that led to the
diagnostic. It is recommended that the
alarm limits, which are registered in the
system, appear in these spectra, and that
annotations of the most important
frequencies that led to the spectrum
interpretation should be made.
The CSI MasterTrend Software offers the
possibility to file the spectra in files .BMP or
.PCX in such a way that any text processor
could retrieve them.
In figure 11.2, we show a model report,
elaborated with the information obtained
from a Symetro reducer that presented
serious pitting problems.
No spectrum was obtained after the pinion
replacement; consequently, the report of
the obtained results, which are explained in
the following section, will show another
model case.
In conclusion, a vibration analysis report
should not contain complicated technical
information that could confuse the
maintenance personnel. One should explain
the problem in a simple manner and make
very clear recommendations.
11.3 Report of the results obtained
This is one of the most important reports in
the Predictive Maintenance System because
it is directed to the Plant Management.
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This report should be elaborated in a simple

and clear manner in order to attract the
attention of the high administrators and
consequently obtain their support for the
continuation of the system.
The acquisition of the new predictive
technologies will depend greatly on their
support, which will also serve as the
necessary boost for the training
improvement of the Predictive Maintenance
personnel.
In this report, one should include the
problems that were detected thanks to the
vibration analysis and the correction results.
The following should be mentioned in the
report:
WORK DONE DURING THE PROBLEM
RESOLUTION
It should contain brief description of the
action taken to resolve the problem,
involving the maintenance personnel that
collaborated in problem solving.
It is recommended to include comparative
spectra where the improvement is shown.
Special attention should be paid to
presenting these spectra.
The axle frequency scale and the axle
amplitude scale will need to be similar in
order to avoid confusion when the reader
observes them.

PRECEDENTS It will be very easy to appreciate the

achievements in the previously described
A brief description of the failure record presentation. Bellow, we present a model.
pertinent to a specific machine should be
included. It is recommended to use the
data from the last two years.

BRIEF DESCRIPTION OF THE PROBLEM

In this section, a brief description of the

analysis results will be made, paying
attention not to use too complex technical
results, only the most important
information.

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20 de Agosto de 1993

August 20, 1993

For: Ing. Ricardo Navarro / General Director

Ing. Mariano Romero / Production Director
Ing. Roberto Marrjo / Maintenance Director

From: Ing. Jorge Gutiérrez Villarreal / Predictive Maintenance

Subject: Vibration analysis report and the improvement in the machine M-85 in the stretching
area.

1. PRECEDENTS

In the last 24 months, the stretching machine M-85 required continuous transmission bearing
replacements; they have been replaced approximately every six months. The total stoppage
time due to repairs was 33 hours in the last 24 months.

As the plant is operating at its full capacity, these unexpected stoppages have directly
impacted the sales because 80% of the raw material is processed through it. The estimated
losses due to this stoppage time rise to $235,000.00 with respect to sales, $24,800.00 in
maintenance costs and the personnel's extra time.

External personnel were balancing the inertia steering wheel without satisfactory results. It
was decided to make a vibration analysis with the instruments acquired by the company. It
was managed to find the excellence range, and we expect a continuous operation of this
production line with high reliability. This machine was annexed to the Predictive
Maintenance System that is in its implementation stage.

An analysis reports follows, as well as the results obtained.

2. PROBLEM DESCRIPTION AND THE IMPLEMENTED CORRECTIONS

High-level vibrations were detected at the entrance of the reducer, especially in the vertical
direction and at the pinion spinning frequency. The vibration in the horizontal directions was
in average less than 30% of the vertical readings. Looseness was suspected at the base and it
was checked with hands. It was discovered that 3 of the 4 anchor screws were loose.

In coordination with the maintenance personnel, we proceeded to tighten the screws while
we monitored the vibration levels in order to stop the process in case of an increase in
vibration levels that could occur if the assembly motor-reducer is destabilized during the
screw tightening.

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You will find bellow, the comparative spectra before and after the screw tightening. In a
planned stoppage, we shall proceed to apply a cement grout to eliminate looseness in one
anchor that could not be tightened.

Sincerely,

Ing. Jorge Gutiérrez Villarreal

Analyst
Predictive Maintenance Department

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TYPICAL ARRANGEMENT OF
EQUIPMENT WITH MEASUREMENT POINTS
Description of the problem:
Recommendations:
Equipment:
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Identification:
Section:
Monitoring date:
Date of the general report:
Analyst's name:
Analyst's signature:
Work order number:__________________
VIBRATION LEVELS:
REPAIR PRIORITY:
SEVERE, greater than 2X LF
IMMEDIATE ATTENTION
VERY HIGH, greater than LF
PROGRAM IN _________ DAYS
HIGH, grater than 0.9X LF
REPAIR NEXT MAINT.
REGULAR, greater than LA
MONITOR IN _______ DAYS
NORMAL, weaker than 0.9X LA
CONTINUE MONITORING
LA = alarm limit = ___________ in./sec.
LF = failure limit = ___________ in./sec.
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Equipment: Symetro Reducer Mill M. Primes 2

TYPICAL EQUIPMENT DISTRIBUTION WITH Identification: MMP-2
Section: Raw materials mill
MEASUREMENT POINTS Date of monitoring: 31-08-93
Date of report writing: 02-09-93
6V 8H 5V Name of the analyst: Oscar Jiménez Yenny
6A 8V 5A Analyst's signature:
G6A 8A G5V

N3= 42 N4= 176 N3= 42 No. of work order: CMV-0188-9880

SYMETRO REDUCER VIBRATION LEVELS:

SEVERE, greater than 2X LF IMMEDIATE ATTENTION

VERY HIGH, greater than LF PROGRAM IN _________
DAYS
HIGH, grater than 0.9X LF REPAIR NEXT MAINT
N2= 297 N1= 38 N2= 297
REGULAR, greater than LA MONITOR IN
_______ DAYS
NORMAL, weaker than 0.9X LA CONTINUE MONITORING
2H,G2H
7V 4V
7A 1V,G1V 4A LA = alarm limit = 0.12 in./sec.
G7V 0A,G0A G4V LF = failure limit = 0.15 in./sec.

Problem description:

1. High vibration levels were detected at the point IV

located at the reducer's entrance. The vibration is 0.762
in./sec. at gear frequency and it shows lateral bands
distanced from each other at the spinning frequency. The
gear frequency is 38X RPM spin.

2. The vibration at the point 2H shows also the components

of the pinion gearing frequency.

3. The probable cause of this vibration is the excessive

pitting at the pinion entrance.

4. The reducer bearings are in good condition.

5. There is a potential risk of the second step reduction

crown getting damaged if the reducer continues working with
the same vibration levels.

Recommendations:

1. Take a sample of the reducer's oil and analyze it in order

to obtain information about metal particles that are found in
oil.

2. Have a reserve pinion ready at the moment of reducer

inspection.

3. Stop the unit, inspect the pinion entrance and replace it

in case of an excessive pitting evidence. Adjacent crowns
should be checked also.

4. It is recommended to immediately monitor the repair to

make sure it was realized correctly.

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CHAPTER 12
Importance of Precision
Corrections
12.1 Introduction
In this chapter, we shall talk about the
definition and importance of precision
corrections. It was previously mentioned
that the two major vibration causes in the
rotating equipment are lack of alignment
and unbalance. Consequently, we shall
focus on the precision alignment and
balancing.
12.2 Precision alignment
Precision alignment is the process with
which an adequately trained person, with
equipment and necessary tools, takes the
time and makes an effort to make two or
more equipment parts stay aligned within a
previously established tolerance.
This tolerance will depend on the spinning
velocity of the equipment, coupler type,
distance between two axles and its function
while it operates under certain temperature
and load conditions. In other words, it is a
result of a technological alignment that is
adequately implemented.
On Table I, the acceptable tolerance for the
precision alignment jobs is presented. This
table is an analysis summary for the tables
used by Benchmark companies today.
The precision alignment is not necessarily
related to a specific method with which it is
performed. For example, a person with
very little training and with a laser
alignment system will make a worse
alignment than a person with great ability
and experience that implements a
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traditional alignment method, as are "face
and edge" or "inverted indicators".
The precision alignment is very important
because it will help minimize the damage in
couplers, bearings, seals, etc., and reduce
the vibration levels in the equipment.
Poorly aligned or not aligned equipment will
generate too much vibration in and/or
effort on the driving and driven equipment.
Consequently, the bearings, seals, couplers,
etc. will fail in the most inopportune
moments.
In general, all the equipment should be
precision aligned, either when it is installed
for the first time or when a program of this
type is initiated.
However, it is practically impossible to align
all the equipment from one day to another.
So, it will be necessary to classify the
equipment according to its importance in
the process, maintenance costs and failure
frequency in parts (bearings, couplers,
etc.).
Basing ourselves on the previous statement,
we shall present an alignment verification
and precision alignment corrections
program in order to accomplish the goals of
precision alignment with all the prioritized
equipment within a reasonable time period.
It is amply recommended to take readings
of the workflow before initiating an
alignment program, and to retake readings
after precision alignment in order to
calculate the electric energy savings. It is
normal to obtain savings greater than 10% in
electricity consumption.
Another important part of the precision
alignment is the pole alignment. Because
one might think that the belts are flexible,
in many occasions one does not pay due
attention to the precision alignment
between poles.
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An excessive lack of alignment between
poles will generate high axial vibration
levels, reducing the life expectancy of the
belts and bearings, and even wearing the
poles. It will be very important to check
that both poles are actually concentric; if
not, there will be high radial vibration.
Generally, one aligns the pulleys taking as
reference their faces, however one should
be careful in establishing equal distances
between the face and the first groove in
both pulleys. Otherwise, there will be a
lack of alignment between grooves and
consequently between belts, as it is shown
on Table 12.1. A correct alignment
between poles implies aligning grooves, and
not the faces of both pulleys.
12.3 Precision balancing
The term balancing is defined as a
"procedure which verifies the rotor mass
distribution, and if necessary, it is adjusted
to ensure that the residual unbalance or the
vibration at the corresponding frequency
are within the specified limits". The table II
shows the balancing tolerance for rigid and
flexible motors according to precision
standards.
LACK OF PULLEY
GROOVE ALIGNMENT
Table 12.1
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As in the case of precision alignment, it is
important to make previous verifications
before performing precision balancing.
Among recommended verifications, we
emphasize the following: concentricity of
axles, couplers and pulleys, bearing
temperatures, condition of the attachment
screws, condition and type of transmission
belts (if there are any), structure conditions
(looseness, cracks, corrosion, etc.), base
and foundation conditions, etc.
Two of the most important predictive
maintenance system functions are the
problem identification and the prolongation
of equipment's durability. The vibration
analysis is much more precise when there
are no high spinning frequencies caused by
an unbalance.
The lack of alignment and other vibration
causes are more easily detected if one has
faith in precision balancing. In addition,
any residual unbalance or induced vibration
wastes energy, reducing efficiency and
shortening the durability of bearings and
other components.
The precision balancing is undertaken in
order to maintain the product quality,
reduce the production time loss, increase
the life of equipment's components, save
energy and increase the operational safety.
It is also very important because it can
decrease maintenance costs.
12.4 Bases and anchoring
There was a lot of discussion, during the
precision alignment and precision balancing
about the importance of examining the
conditions of the equipment's base and
anchoring.
To attain the precision levels, it is
fundamental to be able to count on
adequate bases and anchoring, and they
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1316 – SHELF 16
-MIH MOTOR SIDE HORIZONTAL-CHARGE

should be in good condition. Some might
say, "The foundation for a good analysis is a
good base verification".
A typical problem with bases and
foundations is shown bellow. The spectra
shown in Tables 12.2 and 12.3 correspond to
the horizontal readings on the charge side
of an 1,000 HP motor that drives a mill of
an iron plant.
This motor is relatively new as it was
installed 3 months before this monitoring in
order to increase the power in the
lamination process. The anchoring
modifications were not made, and the
motor now weighs double of its original
weight.
It is recommended to stop the unit and
repair the deteriorated section of concrete,
applying grout cement to achieve high
resistance in a short period of setting time.
The results obtained with this repair can be
observed in the Table 12.3 spectrum.
Once this motor was functioning at full
power, spinning frequency vibration of only
0.17 in./sec. was observed. This vibration
amplitude is within this equipment's limits.
This example is sufficient to underline the
importance that bases and anchoring have
in achieving low levels in vibration and
prolonging equipment's durability when they
are used correctly.

Before taking the reading, a revision by

hand was made at the foundation, finding
that one of the anchors was completely
detached from the foundation. In the
spectrum of the Figure 12.2, one observes
that the original vibration at spinning
frequency was 1.29 in./sec.
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Table 12.2 Spectrum taken before the anchor repair

1316 – SHELF 16
-MIH MOTOR SIDE HORIZONTAL-CHARGE

Table 12.3 Spectrum taken after the anchor repair.

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12.5 Documenting the precision the working conditions of the equipment

corrections through precision balancing and alignment.

One of the stages that takes most time
when making an alignment is the
verification and correction of the pre-
alignment. For example, before initiating
an alignment job in equipment, the first
thing that should be done is ensuring that
both axles and couplers are concentric.
Then, one should see whether there is a
loose leg, adverse conditions in the screws,
base, anchor, etc.; and afterward, one
should correct the problem.
Each one of these conditions will have an
effect on the equipment's operation and
alignment.
The documentation of the verifications and
corrections realized will be very useful
because the future realignment's time
consumption will be considerably shorter.
For example, a loose leg will not appear
suddenly among alignment tasks. If the
problem was found and corrected, it will
not be necessary to check the loose leg
again.
The operation costs could be decreased the
following way:
- energy saving by decreasing the energy
consumption
- increase the bearing duration by reducing
the load and temperature.
- cost reduction in maintenance labor
- cost reduction in parts replacement
- product's quality increase
- decrease the production time loss
If we consider the fact that the energy costs
directly influence the plant's profitability,
we can deduce that if we improve the
operational conditions of the inefficient
equipment, we will contribute directly to
the increase in profits. In this step lies the
importance of precision correction, it is
worth trying to implement it.

For a balancing job, if the influence

coefficients, the distribution of the
correction weight, the documented
quantities and the sensors are all in place;
when the technician proceeds to balance
the equipment, he could repeat initial
parameters without a great time loss.

As a result, a technician will be able to

determine a correction weight without
having to place again a trial weight, saving
time, money and effort.

12.6 Financial savings

It is unquestionable that considerable

amounts of money could be saved improving

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TABLE 1 TOLERANCE FOR THE PRECISION ALIGNMENT

1. SHORT COUPLERS (DIRECT COUPLING WITHOUT SPACER AXLE)

EXCELLENT ACCEPTABLE

SPINNING PARALLEL ANGULAR PARALLEL ANGULAR

FREQUENCY IN (mils) (mils/in. (mils) (mils/in. coupler
RPM of coupler diameter)
diameter)

< 500 5.0 1.5 6.0 2.0

500 - 1250 4.0 1.0 5.0 1.5
1250 - 2000 3.0 0.5 4.0 1.0
2000 - 3500 2.0 0.3 3.0 0.5
3500 - 7000 1.0 0.25 2.0 0.3
> 7000 0.5 0.2 1.0 0.25

2. SPACER AXLE

EXCELLENT ACCEPTABLE

SPINNING PARALLEL/LONGITUDE INCH PARALLEL/LONGITUDE INCH

FREQUENCY IN OF THE SPACER AXLE OF THE SPACER AXLE
RPM (mils/in. of coupler diameter) (mils/in. of coupler diameter)

< 500 1.8 3

500 - 1250 1.2 2
1250 - 2000 0.9 1.5
2000 - 3500 0.6 1.0
3500 - 7000 0.3 0.5
> 7000 0.15 0.25

Source: CSI tolerance for the precision alignment

Note: In case the coupler tolerance is inferior, one should use the tolerance specified by the
provider

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TABLE II. TOLERANCE FOR THE PRECISION BEARING ACCEPTANCE

SPINNING FREQUENCY EQUATION USED TO CALCULATE THE PERMISSIBLE RESID

IN RPM UNBALANCE UPER IN GRAMS/INCH

< 150
U PER = 5.018 x W

until 1000
U PER = 113400 x W / N 2

> 1000
U PER = 113.4 x W / N

where:

UPER = permissible rotor unbalance in grams-inch

W = rotor weight in pounds

N = RPM rotor service

For the dynamic balancing in two planes, one should divide the result by 2 and this tolerance will be applie
each measurement plane. Only one plane will be considered when the relation diameter/width of the rotor
greater than 6. In this case, the resulting tolerance will be applied directly to each rotor support.

The balancing provider should offer a Balancing Certificate that confirms that a verification experiment was
conducted after the balancing in which a weight was placed at six different positions (60° each). The certif
weight would be 10 times the residual unbalance that was solicited. These readings should be included in
tabular form certificate and its average value should be shown.

To accept the rotor repair as effectively done, all the readings should be in the range of the promised value
12%. If some readings are outside of this range, the motor should not be accepted.

IMPORTANT NOTE:

For the balancing done in the field where the rotors are balanced on their supports and at the operational
velocity, it is recommended to use an acceptable criteria of 0.05 in./sec. max peak, in horizontal and vertic
positions, taking measurements on the frame supports.

Source: United States marine tolerance, NAVSEA STANDARD ITEM 009-15

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CHAPTER 13 13.2 Management support and plant's

culture
Criteria for the World Class One of the fundamental parts for the
Certification implementation, development and
maintenance of the World Class
Maintenance System is the unconditional
13.1 Introduction support from the Management and an
adequate cooperation among the plant's
In various chapters of this manual, we staff.
mentioned the terms "World Class" or
"Benchmark", but we did not give their The management needs to establish the
definition or explanation. objectives and goals for its system in a clear
and concise manner, emphasizing not only
A "World Class" or "Benchmark" company is the plan for the implementation of new
an enterprise whose administrative techniques but also its expectations for its
organization, production processes, personnel's involvement.
technology, human resources, maintenance
programs and other characteristics are It is essential to establish the Mission for the
worthy of being considered as development maintenance department.
models and/or examples to follow. The
World Class maintenance starts with a clear The relation established with the
understanding of the manner in which the management and the support for the
maintenance should be done. predictive maintenance system from the
line operators should create the adequate
Then, and only then, it is possible to specify social ambiance which should help to
with certainty what human resources are realize the plant's goals and objectives, and
necessary to realize it, which parts are which should be known by everyone
necessary to support its infrastructure and involved.
what systems are necessary to control it.
The consistency of a maintenance
In this chapter, we shall focus on the department and the presence of a
programs and maintenance systems used by dedicated predictive maintenance group are
the World Class companies; as well as the essential elements in the development and
most important criteria for the World Class maintenance of the World Class
Certification. Maintenance program.

In order to evaluate a maintenance system
and be able to compare it with World Class
Systems, it will be necessary to evaluate
each one of its sections or parts, which
integrate the whole program. Bellow, you
will find a summary of each one of the
program's integral parts and the evaluation
standards.
In conclusion, the system should use all the
equipment records and data obtained in the
monitoring stage to identify and program all
kinds of interventions (predictive
maintenance, planned stoppage, equipment
repairs, acceptable levels of repaired
equipment, etc.), with the purpose of
attaining a higher availability of the
machines and estimating the most realistic
maintenance costs.

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13.3 Program organization
A necessary infrastructure should be
developed for an appropriate blend of
corrective, preventive, predictive and
proactive maintenance in order to realize
the objectives of World Class Maintenance.
An effective communication should be
established between the department of
predictive maintenance and the department
of programmed or corrective job
implementation. The predictive
maintenance department will send to the
repair personnel a report containing the
diagnostic of the equipment and corrective
actions.
The department of work implementation
should send to the predictive maintenance
department the information corresponding
to the details pertinent to repairs and
commentaries about special findings.
This type of reciprocal communication will
ensure the success and continuous
development of the program.
The vibration spectrum of equipment before
and after the maintenance is a clear
manner of showing the importance of
communication and the achievement
obtained by operators, mechanics and
managers. The necessary information for
the elaboration of these reports could be
found in chapter 11.
The benefits of the vibration analysis and
other monitoring efforts should be
communicated in an official manner to all
the levels of the organization in a routine
manner.
The World Class companies have a
Computerized Administrative Maintenance
System (SCAM, based on its title in Spanish)
to achieve the previously mentioned goals;
in other words, the automatic integration of
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corrective, preventive, predictive and
proactive maintenance.
The computerized program should also
interconnect the purchase and storage
departments in order to generate, with
respect to needs and monitoring conditions,
the work orders for part purchases that are
necessary in the performance of an
effective maintenance.
13.4 Predictive maintenance technologies
An evaluation of the percentages of the
equipment included at this time (critical or
no critical) in the monitoring program, in
accordance with the predictive
maintenance implementation techniques
(analysis of the vibrations, thermography,
oil, ultrasonic, etc.) and the manner in
which the rest or the equipment could be
included.
Besides these tasks, the program members
will evaluate the methods and techniques
used for the application of the
aforementioned technologies. In the case
of the vibration analysis, one should review
the parameters and techniques of
inspection, alarm level functions, frequency
or interval monitoring and other aspects of
the program according to the principles
established in this manual.
13.5 Proactive maintenance
A study will be conducted to determine the
use or storage of the proactive maintenance
techniques:
- Development of specifications or
acceptability criteria for the repaired
equipment, either in internal or external
shops, as well as for the new equipment.
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- Use of the advanced techniques (modal It is important to remember that a World

and multi- hannel analysis, demodulation, Class Maintenance program is dynamic and
negative averaging, etc.) for the in constant improvement, and the
determination and solution of the "root maintenance indicator program should be
causes" of the identified problems. constantly evaluated, justified and
communicated to the whole organization.
- Working relation between predictive
maintenance department and the
engineering department in the development 13.8 Examples of the evaluation
and installation specifications for new questions.
equipment.
We shall show a list of questions that can be
- Use of the precision alignment and used to evaluate a predictive maintenance
balancing techniques, with their respective system:
specifications.
13.8.1 Actual situation

13.6 Training development 1. What percentage of corrective,

preventive, predictive and proactive
One should evaluate the progress and maintenance practices are in use today?
development of the training program,
basing the evaluation on the principles seen 2. What predictive maintenance
in chapter 3. technologies are used?

3. Are there problems that have frequently

13.7 Maintenance indicators reappeared and that could not be resolved?

As it was mentioned in chapter 10 of this 4. What mechanical and electric problems

manual, the maintenance indicators are a are most common?
fundamental part of the development and
continuity of the Worlds Class Maintenance 5 What maintenance percentage is related
program because they will show us the to emergency work orders?
progress and development of the program as
well as its success or failure.
13.8.2 Implemented predictive
The results of the vibration-monitoring technologies
program as well as the effects of the
predictive technologies should be 1. What percentage of critical equipment is
documented and published on the monthly included in the vibration analysis program?
bases.
2. What is the monitoring frequency or
In particular, the number of failures found interval?
and corrected every month, the financial
benefits accumulated in maintenance 3. Is spectral monitoring analysis program
expenditures and the indicator of the plant's used routinely?
availability should be shown to all
administrative and operational 4. What alarm criteria are used?
representatives.

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5. Are thermography studies conducted at

the plant?
6. What coupler alignment method is used?
13.8.3 Maintenance personnel
4. What is the estimated inventory cost of
replacement parts?
5. What is the estimated annual cost of the
preventive maintenance program?

1. Who is in charge of the predictive

maintenance program?

2. How many members are assigned to the

maintenance program?

3. How many persons have received

predictive technology training?

4. How many vibration analysis courses are

given at the present time?

13.8.4 Maintenance reports

1. Are all the machine failures registered?

2. What information is filed in the repair

department?

3. What departments are involved in the

maintenance reports?

4. Are the work orders automatically done?

5. What personnel is involved in the work

orders?

13.8.5 Maintenance indicators

1. What financial support is offered to the

maintenance department?

2. What is the general tendency of the

annual maintenance costs?

3. How many production hours were lost

because of the equipment failures last year?
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CHAPTER 14
Glossary
ACCELERATION
A measurement unit of force acting upon an
object usually measured in G's where a G
represents the gravity pull.
A sensor used for measuring the
acceleration is known as accelerometer.
ACOUSTICS
Acoustics is the study of machine sounds.
The CSI 2115 recorder can measure and
analyze the intensity level of a global
sound, narrow band spectra and thirds of an
octave.
ALARM LIMITS
Amplitude that defines an alarm condition
of the equipment monitored.
ALARM STATUS
The information about the computer
condition that appears on the screen of the
analyst for each measurement and which
contains the alarm level for this particular
point.
ALARMS
Indicating that characteristics of the
vibration have changed significantly.
ALERT
Defined alarm level, calculated by the data
management system Master Trend, which
indicates that the machine is approaching
the failure level. In reports, it is notified
as: Alarm "C".
ALIAS
A happening that results in an erroneous
spectral frequency when the frequency
signal shown is 0.5 times greater than the
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model. The analyzers CSI have anti-alias
filters that eliminate these errors.
AMPLIFICATION
It is a way of increasing the signal
amplitude with a desired factor in order to
facilitate the signal processing.
AMPLITUDE
It indicates the force (magnitude expressed
in RMS, peak, peak-peak, average, or CD of
a measured signal).
ANALOGOUS INTEGRATION
Converting an acceleration signal to the
velocity value, or a velocity signal into
distance. The analogous integration is
superior to its digital counterpart, because
it produces a better estimation of low
frequency components in the vibration
spectrum, and thus increasing a dynamic
range.
ANALOGY
Converting an acceleration signal to its
velocity, or converting a velocity signal into
a distance. The analogous integration is
superior to the digital method because it
can produce a better estimation of low
frequency components; besides that, it
improves the dynamic range in a vibration
spectrum.
ANALYSIS PARAMETERS
They divide the spectrum by frequency, into
bands that are individually observed and
analyzed.
AUTO-RANGE
It is an automatic adjustment process of the
entering signal into the recorder, and it also
regulates the amplitude of the recorded
signal. This process produces an amplified
dynamic range.
AVERAGING
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Recording information about vibration
levels, averaged over a number of
measurements, to minimize the fluctuation
influence produced by aleatory signals
(noise).
BAND WIDTH
Frequency range used to analyze different
frequency levels, high and low, and which
will record the information. The bandwidth
is specified with the maximum and
minimum frequency range.
BLOCKS
Memory space units used in reference to the
database. A block is equivalent to 0.5
Kilobytes.
BODE DIAGRAM
A graphic representation that shows how
the amplitude at 1X RPM and its phase
change, when the velocity changes in RPM.
It is recommended that these values are
always related to the starting and stopping
of the machines in order to identify the axle
resonance and other signal characteristics.
BPFI
This term is used to identify failures in a
bearing component. In this case, it is the
ball's (or roller's) passage frequency over a
crack or an uneven spot on the inside track
of a roller.
BSF
This term is used to identify failures in the
bearing component. In this case, it is the
spinning frequency of the ball (or roller)
when it moves along the internal or external
bearing track.
CALIBRATION
Thanks to this process the instruments and
transducers are reviewed and adjusted
periodically to register more precise
readings.
COEFFICIENTS OF INFLUENCE METHOD
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Calculating method, used by the analyst to
solve balancing problems.
CPM
Cycles per minute. It is the same as RPM
(revolutions per minute).
CREST FACTOR
It is the relation between the peak value
and the RMS value of a signal: A simple
signal of simple frequency has a crest value
of 1.414. Aleatory noises have a crest
factor of approximately 3. The signals that
have high impulse content have a higher
crest factor. This factor can be used to
check impacts, like those caused by bearing
defects.
CURSOR
An indicator that can be wielded manually
and it can be moved on the screen where
the spectrum is shown, indicating at each
point, where it is positioned, the point's
magnitude and frequency values.
dB
Decibels. It is a relative unit that can be
defined in logarithmic notions as dB = 20 log
10 X/X ref.
In acoustics, the reference level represents
the limit of human perceptions on the sound
level, and it is equal to 2 x 10 - 5 newtons
per meter squared.
DIAGNOSTICS
The techniques used to analyze and identify
problems in machines.
DIGITAL INTEGRATION
Converting acceleration into velocity or
velocity into distance; first collecting the
information and then digitizing the
spectrum of each frequency. The digital
integration is less recommended than the
analogous integration because it produces
low frequency components in a spectrum.
The digital integration is included in the
Master Trend System in order to be
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compatible with the information registered
through the Equipment model 2100.
DISTANCE
It refers to the distance that an object
travels, usually measured in thousandths of
an inch or millionth of a meter (micron).
The distance is measured with Eddy current
sensors representing the real movement of
a spinning axle.
Sometimes, seismic or piezoelectric sensors
are used to integrate the recorded
information in units used for distance. In
this case, the movement represents the
distance relative to the axle, taking as a
reference the surrounding frame or chassis
where the sensor is placed.
EQUIPMENT SIGNATURE
A spectrum used as reference, usually
equipment’s first registered spectrum.
ENTIRE PARAMETERS FOR ANALYSIS
A process that divides the spectral
frequency into bands which are
contemplated and analyzed; these can be
grouped in units of six parameters which
also include instructions for the analyst
about the manner in which one can record
information.
FFT
Fourier fast transformation. A calculation
done by computer and it has the purpose of
converting the signal from its time mode to
the frequency expressed on a diagram.
FILTER
A contrivance that removes certain signal
frequencies while it conserves the rest of
the signal.
FREQUENCY
Number of times an event repeats itself in
time units; usually it is expressed in Hertz
(Hz) or cycles per minute (CPM).
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FUNDAMENTAL FREQUENCY
The frequency peak to which the harmonic
waves are related. 1X RPM is an example of
fundamental frequency.
FUNDAMENTAL
The primary frequency of the rotation of a
machine (1 X RPM), it usually causes the
highest energy peak of the spectrum.
G's
Measurement unit for acceleration; 1G
represents the gravity pull at sea level.
HANNING
A numeric technique used to avoid peaks in
spectrum in function of the frequency,
avoiding the sprawling due to the
phenomenon called "leak".
The Hanning window is recommended for
the majority of frequency analysis
measurements in which the signal is stable.
HARMONIC WAVE MARKER
A marker with a box or square-like
appearance in the spectrum displayed which
indicates harmonic peaks of a fundamental
peak.
HARMONIC WAVES
Fundamental frequency multiple
HERTZ
Frequency in cycles per second.
HFD
High frequency measurement. The
vibration amplitude in G's on a wide band
from 5k Hz to 20k Hz or more.
INTEGRATOR
It offers options for different ways of
recording the signal: analogous or digital.
See these two previously described points.
MEASUREMENT POINTS
See the definition of point.
MIL'S
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Measuring unit for distance (thousandths of
an inch)
MODEM
Equipment, that allows communication
between the computer server and the
recording equipment, using telephone lines.
MULTI-PLANE BALANCING
A method which balances an element in a
machine, and which permits to measure the
unbalance in various planes along the axle.
The counter-weight measures are added to
each plane. The balancing process in a
multi-plane, or the opposite of balancing in
one plane, is recommended when the
machine has various rotational elements,
such as: crankshaft, coupler and elements
that are connected directly to the axle and
cautiously distanced one form anther.
NOTES
Specific observation that can be obtained
from a measurement point of a machine. It
includes officially stored information and
notes left by the user which have been
typed through a computer or hand written.
NYQUIST DIAGRAM
A polar diagram where amplitude
components - peak at 1 X RPM - and its
phase component interact in function of the
velocity change. The diagram Nyquist is
used during the starting and stopping of
machines to identify resonance in
transmission axles.
OUTSIDE OF THE ROUTE
An option that permits the recording and
storing of the information in measurement
points which are not defined on the planned
route.
OVERLAPPING
It is a function that accelerates the
information recording of low frequencies.
The overlapping range for the CSI 2115 is
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from 0 to 80% with the recommendation to
apply a 50% value.
PEAK
The strongest signal that can be observed in
a wave shape, in time mode. For the
sinusoidal signals, the peak signal is always
1.414 times the value of the RMS signal. For
the no sinusoidal forms, the peak level is
often greater than the result that this
equation could produce.
PEAK-PEAK
Difference between the maximum and
minimum values of a signal during a given
period. For the pure sinusoidal waves, the
peak-peak level is twice the peak signal and
2.828 of the RMS value. For the no
sinusoidal waves, the peak-peak level is
often greater than the result that this
equation could produce.
PERIOD
Time required to complete a cycle of a
periodic signal.
PHASE
The phase of 1 X RPM represents the axle
position of a machine expressed in degrees
(from 0 to 360) according to the
tachometer's pulse, where the highest
vibration is appreciated.
PLANE
Defines one or more revolving elements of a
machine that is going to be balanced. Each
plane is perpendicular to the line that
defines the rotation axle.
POINT
Any place on a machine where the
information can be recorded. The
"measurement point" is an equivalent term.
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PONDERATION
A method to conform frequencies that will
be applied to a spectrum based on an
answer to a frequency detectable to the
human ear. The resulting spectrum
represents the intensity of various levels
which can be detected by the human ear.
PREDICTIVE MAINTENANCE
The monitoring technology for periodically
monitoring the machines' condition in order
to detect failures, probable time of break
downs, total failures and to program
stoppages in order to repair components,
avoiding in such a way excessive costs and
production loss.
REAL TIME
Acquisition of the continuous information,
as the spectrum in FFT.
RMS
The magnitude of a calculated or measured
signal, using the mean square root. It is
equal to 0.7071 times the peak value of a
pure sinusoidal wave.
ROUTE
One or more machines and their respective
measurement points, organized in an
efficient sequence for the sake of
information recording.
RS 232
It is a normal communication, synchronic
serial, signal. The cables for connecting
computer links and computers or modem
equipment are called RS 232.
SHOCK TEST
A test used to determine the structural
resonance of a machine.
SIGNAL INTEGRATION MODE
It permits the selection of the signal
integrating mode: analogous or digital. See
integration.
SPECTRA
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A diagram where the frequency components
and their magnitude (amplitude vs.
frequency) are shown in a dynamic signal,
as a vibration.
STATION
In the CSI system, it is the grouping of the
machines in a plant, with the objective of
implementing the predictive maintenance
system. All the machines from one specific
area can be included or they can be sub-
divided in routes for the information
recording.
SUB-HARMONICS
Vibration frequencies which are whole
fractions of the spinning velocity. For
example: 1/2 X RPM, 1/3 X RPM, etc. or
another fundamental frequency.
TACHOMETER
Pulse signal used to measure the spinning
velocity of the axle. It can also be used for
the acquisition of the dynamic information.
TENDENCY ANALYSIS
It marks a number of measurement points of
a specific parameter vs. time.
THIRDS OF AN OCTAVE
A method for measuring a signal,
contemplating the signal levels in the filters
that have a width of 1/3 of an octave.
TRANSMISSION RANGE
The unit used to indicate the data
transmission velocity in a serial connection
of a computer system. The model 2115
accepts baud ranges from 300 to 57.6K
bauds.
TRANSITORY
An unstable signal of finite duration. One
often refers to it in the starting and
stopping of a machine.
TRIGGER
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After receiving a specific signal from the

sensor, the trigger makes the recorder start
recording information.
VELOCITY
A measurement of a distance traveled by an
object in relation to time. The vibration
levels are measured with a seismic sensor.
The velocity can also be measured
integrating the acceleration signal.
VISCOSITY
Fluid resistance to cutting effects. It
usually decreases when the temperature
increases.
WAVE SHAPE
Analogous or digital representation of a
function or signal, represented as amplitude
vs. time.

VIBRATION PARAMETERS WINDOW

There are six bands of limited frequency
which measure vibration signals. In the
computer, these parameters are pre-
defined and categorized for each
measurement point using the Master Trend
data base. They are also known as
individual analysis parameters.
See the information related to window in
"Hanning".
XCOM
Communications program that permits the
computer to transfer routes and data
information to and from the analyst.

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CHAPTER 15
Annexes

STATIC UNBALANCE

PHASE SPECTRUM

1X radial

ADDITIONAL COMMENTARIES

The static unbalance presents vibration levels that are in phase and stable. The vibration
amplitude varies according to the spinning velocity; in other words, an increase equivalent to 3
times the spinning velocity will cause an increase of 9 times the vibration level.

The vibration of 1X RPM will always be present, and it will dominate the spectrum. This type of
unbalance is corrected adding a weight in the plane of the rotor's center of gravity.

The rotors that usually present this type of unbalance are narrow, and if the diameter/width
relation is greater than 10, the problem will be resolved after a simple static balancing.

When this relation is less than 10, it is recommended to make a dynamic balancing in the two
planes.

PAR UNBALANCE

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PHASE SPECTRUM

1X

Radial and axial

reading

ADDITIONAL COMMENTARIES

Par type unbalance presents phase at 180 degrees on the same axle and in the radial direction.
The vibration at 1X RPM will always be present, and it will dominate the spectrum. The
vibration amplitude will vary according to the spinning velocity.

It can cause high axial and radial vibrations. One needs to put weights in both planes to correct
it. The 180 degrees difference in the phase will apply to both the vertical and horizontal axles.

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ECCENTRIC ROTOR

PHASE SPECTRUM

e 1X ventilator

Radial reading
+

1X motor

ADDITIONAL COMMENTARIES

The eccentricity occurs when the rotation center is moved from the geographic center of
pulleys, gears, bearings, motor rotors, etc. The highest vibration will be at 1X RPM of the
eccentric component and in the direction of the imaginary line that unites the central lines of
both rotors.

The comparative phase reading between the horizontal and vertical axles will be 0 or 180
degrees, indicating both movements in straight lines.

When trying to balance eccentric rotors, the vibration is lowered in one of the radial directions
but it is increased in the other, depending on the eccentric quantity.

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CANTILEVER FAN

PHASE SPECTRUM

1X

Radial and axial

reading

ADDITIONAL COMMENTARIES

The installed rotors' unbalance in cantilever causes high vibration at 1X RPM in axial and radial
directions. The axial readings will be in phase when the radial readings are unstable. These
cantilever rotors will usually have both types of unbalance (static and par), each one requiring
corrections.

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FLEXIBLE ROTOR

PHASE SPECTRUM

1X
Radial
reading

2X

The bent axles cause high axial vibration with phase axial readings of 180 degrees between
machine supports. The prevailing vibration will be at 1X RPM if the bending is close to the
axle's center, and at 2X RPM if the bending occurs at the ends.

(Be careful taking axial phases with respect to the sensor's orientation for each axial reading. If
one wishes to reverse the direction of the sensor, one should not forget to subtract 180° from
the reading).

The phase radial readings will show movement "in phase" because the movement that was
caused by the bending will occur on both supports. Thus, the amplitudes will be similar on the
supports.

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ANGULAR LACK OF ALIGNMENT

PHASE SPECTRUM

1X
2X
Radial
reading
3X

The angular lack of alignment is characterized by the high axial vibration and differences in
phase of 180 degrees from one side of couplers to the other. Typically, high axial vibrations
with values of 1X RPM and 2X RPM will be shown.

It will not be strange to observe 1X, 2X and 3X components dominate the spectrum. These
symptoms could be a problem indicator of a contact between coupler faces.

At times, the angular lack of alignment is more critical when the thermal increase at each
machine support is not taken into account.

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PARALLEL LACK OF ALIGNMENT

PHASE SPECTRUM

2X Radial
1X reading

3X

The parallel lack of alignment presents similar symptoms to those of the angular lack of
alignment, but with high radial and phase vibration differences of 180 degrees between
couplers. The 2X RPM vibration will usually be greater than the one presented at 1X RPM, but
its relative magnitude at 1X RPM will be determined by the coupling type and its fabrication.

When either of the two types of lack of alignment, angular or parallel, becomes severe, it can
generate high amplitudes in the subsequent harmonic waves (4X - 8X) and in the higher
harmonic waves, apparently similar to the symptoms of mechanical looseness.

The coupler type will be very important in the spectrum's behavior when the lack of alignment
is severe.

It will be very important to take into account the thermal increase when calculating the lack of
alignment value in order to avoid high vibration levels.

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RESONANCE

PHASE SPECTRUM

phase

Amplitude 90°
180°
Second critical

The resonance occurs when a forceful frequency, such as unbalance, lack of alignment, etc.,
coincides with the system's natural frequency, and it can cause substantial amplifications in the
vibration levels that can result in premature and even catastrophic failures.

The natural rotor frequency can get excited, but usually it originates in the base of the support,
foundation, and gearboxes and even in elastic bands. If a rotor is in the resonance state or
close to it, it will be almost impossible to realize a balancing due to the great phase changes
(90° in resonance, 180° passing the resonance threshold).

Sometimes, it will be necessary to change the system's natural frequency.

The natural frequencies do not get modified with the operation's velocity change, this
characteristic facilitates their identification.

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MECHANIC LOOSENESS

1X
Leg base
Plate base
base Radial
reading

This type of mechanic looseness is caused by looseness or weakness in the leg area, base plate
or machine's foundation. Deteriorated gout, loose base screws or a rickety leg can cause it. A
phase analysis will show 180 degrees of approximate difference in the direction between
various components that play an important roll in the machine's stability.
2 Radial
1 reading
0.
5 3

This type of machine looseness is caused by loose screws in the strengthening plates and cracks
in the frame or supports..
2X
1X

3X

10X
0.5X

1.5X

7X
4X

6X

8X
9X
5X

This type of mechanical looseness is usually caused by the inappropriate contact between rotor
components causing multiple harmonic waves due to the no linear response of the loose
components with respect to the dynamic forces coming from the rotor. It truncates the wave
shape. At times, this looseness is caused by an inappropriate contact between an internal
bearing track and its axle, excessive play in the strengthening plates, or by an impellent or
loose axle fan.

The phase is unstable and it can vary a lot from one reading to another, especially if the rotor
changes positions on the axle from one start to another. This looseness is highly directional,
causing considerable differences in vibration levels with possible increases of 30 degrees if the
radial readings are taken near the support.

As it can be seen in the spectrum, the looseness will also cause multiple sub-harmonic waves
whose value will be at 1/2 or 1/3X RPM (0.5X, 1.5X, 2.5X, etc.)

FRICTION BETWEEN PARTS

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SPECTRUM

Radial reading
1X 2X 4X
.5 1.5 res
X X 3X on
2.5 an 4.5
X 3.5 ce X 5X
X

ADDITIONAL COMMENTARIES

The rotor friction produces similar spectra to those caused by mechanical looseness when the
rotating components make contact with stationary parts. The friction can be partial or along
the whole surface. It usually generates a series of harmonic frequencies, exciting one or more
resonance.

Sometimes, harmonic waves are presented (0.5X, 1.5X, 2.5X, etc.), depending on the natural
frequency of the rotor. The friction can excite some high frequencies, similar to the noise
produced when the chock is forcefully applied against a blackboard.

This problem can be serious and last for a short time when an axle rubs against a strengthening
plate of a Babbitt, but less serious than the case in which the axle makes contact with a seal, or
when an agitator grazes the walls or a tank, or when the dustbin or a coupler makes contact
with the axle.

Truncated and flattened wave shape

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FLAT STRENGTHENING PLATE (BABBIT)

2X
WEAR AND TEAR

1X

3X
AND EXCESSIVE LOOSENESS

10X
7X
4X

6X

8X
9X
5X
The final stages of wear and tear in strengthening plates are normally characterized by a whole
series of harmonic waves (up to 20). The flat strengthening plates that cause friction emit high
vertical amplitudes in comparison with horizontal readings. The strengthening plates with
excessive looseness will have high vibration levels caused by unbalance and residual lack of
alignment. These vibration levels would be smaller if the looseness were not excessive.

INSTABILITY CAUSED BY OIL Radial

SQUIRTS .42-.48 reading
+ 1X

The instability caused by the oil squirts at a frequency between .42 - .48X RPM is at times very
severe. It is considered excessive when its amplitude exceeds 50% of the existing clearance in
the strengthening plates. The oil squirt is an excited vibration when it causes deviations from
the normal operation (attack angle and eccentricity), as one oil squirt may make the axle and
the strengthening plate move.

The change in oil viscosity, lubricant's pressure and external pre-charge can cause oil squirts.

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(Nexus A)
Código . . . . .

BALL OR ROLLER BEARINGS

ADDITIONAL COMMENTARIES
FREQUENCY EXCITEMENT ZON STAGE 1
ZONE OF OF NATURAL
1X FAILING The initial indications of bearing problems appear in the zone of ultra-frequency, in the range
BEARING FREQ. of 20,000 to 60,000 Hz. These frequencies are evaluated by a filter HFD (High Frequency
2X

HFD
BEARINGS
3X Detection) and they are measured in G's.

STAGE 1 The value of HFD for this stage will be around 0.25 G's. (This value depends on the machine's
spinning velocity as well as on the choice of the measurement points).

120 KCPM
30 KCPM

STAGE 2 STAGE 2
1X natural bearing
2X3X frequency In this stage, the small bearing defects excite the natural frequency of the bearing
components. These natural frequencies are normally in the range of 30.000 to 120,000 CPM.

Lateral bands appear above and beneath the natural frequency and they correspond to the
failure frequency. The HFD values will be from 0.25 to 0.50 G's.

STAGE 3
STAGE 3
BPFO
BPFI

BPFI

natural bearing
1X
2X

frequency In this stage, the bearing failure frequencies appear. As the deterioration progresses, more
2X harmonic failure frequencies appear and the number of lateral bands increases also, in the
3X failure frequencies as well as around the natural bearing frequency. The HFD continue to
increase, for example from 0.5 to 1.0 G's. In this stage, the wearing is visible and it can be
extended through the whole bearing periphery, especially when there are well defined lateral
bands following any harmonic, failing bearing frequency. It is recommended to change the
bearings at this stage.

STAGE 4
120 KCPM

STAGE 4
30 KCPM

1X high frequency As the bearing sustains major deterioration, the amplitude of 1X RPM changes accordingly.
2X vibration at This amplitude increases and makes its harmonic waves increase. The failing bearing
3X random frequencies and the natural frequency almost disappear and they are replaced by noise on the
spectrum. In this stage, and just before the failure of the bearing, the HFD value goes beyond
3 G's.

The bearing's life expectancy is uncertain at this point.

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BALL OR ROLLER BEARINGS (CONT.)

The equations for the calculation of the frequencies are:

1. Failure on the internal track (BPFI)

BPFI = Nb/2*(1+(Bd/Pd)*cos(τ))*RPM

2. Failure on the external track (BPFO)

BPFO = Nb/2*(1-(Bd/Pd)*cos(τ))*RPM

3. Ball or roller failure (BSF)

BSF = Pd/2Bd*[1-(Bd/Pd)2*cos(τ)2]*RPM

4. Cage/frame failure (FTF)

FTF= 0.5*(1-(Bd/Pd)*cos(τ))*RPM

where:

Nb = No. of balls or rollers

Bd = Ball or roller diameter
Pd = Roller diameter pass
τ = contact angle

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HYDRAULIC AND AERODYNAMIC FORCES

PHASE SPECTRUM

BPF= No. of blades X spin

2X
1 2
BPF

ADDITIONAL COMMENTARIES

A. BLADE FREQUENCY PASS

The blade frequency pass (BPF) is equal to the number of blades multiplied by the RPM spin.
This frequency is inherent to pumps, ventilators and compressors, usually without presenting
any problems. However, when there are high amplitudes in BPF and its harmonic waves, these
can be generated if the clearance between the blades and the stationary parts is not similar
along the whole periphery.

On the other hand, the BPF frequency or its harmonic waves can excite the natural system
frequencies, causing high vibration levels. Besides, this frequency can have high amplitude if
one of the diffusers is detached, or if the rotor is eccentric in relation to the frame. One will
observe high frequency BPF when there are obstructions in the tubes or conduits.

At random 1 random high

BPF 2 BPF
1X vibration
frequency
120

B. FLUID TURBULENCE C. CAVITATION

The fluid turbulence usually occurs in blowers due to the
variations in pressure or air velocity that passes through
the ventilator or conduits. A low frequency vibration in
the range of 50 to 2,000 RPM will be formed.
The cavitations normally generate random vibrations in
the area of high frequency, overlapping at times with the
blade passing frequency and its harmonic waves. The
problem is usually caused by malfunction in the precision
suction. These cavitations can damage seriously the
pump components, eroding the impellers. The typical
sound of this failure is similar to the one that the gravel
would cause passing through the pump.

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GEARBOXES

GMF = gear frequency

1X GMF = no. of teeth X RPM spin
cr
A. NORMAL SPECTRUM ow 1x
n pin GM
2 ion

A normal spectrum of a gearbox will show frequencies of 1X and 2X RPM as well as the
frequency of the GMF gear. The gear frequency GMF will normally have lateral bands around it
and corresponding to the spinning frequency. All the peaks will have low amplitude and there
will be no natural frequency excitement.

B. TOOTH WEAR 1X
cro
wn 1X natural gear
pin frequency 1X
2 ion

A clear indication of the gear tooth wear is the excitation of the spinning frequency of the worn
out gear. The GMF frequency might or might not change in amplitude; however, the lateral
bands will be of greater amplitude when the wearing off is visible. The lateral bands are a
major indicator of worn out teeth, even more than the GMF.
1X corona

GMF
C. GEAR UNDER FULL LOAD
1X piсуn
2X

The gear frequency is usually very sensitive to the load. High GMF amplitudes do not
necessarily indicate a problem, especially if the lateral band amplitudes are maintained low
and if the natural gear frequency was not excited. It is recommended to analyze it under full
load.

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GEARBOXES (CONT.)

D. ECCENTRICITY AND THE 1X

GEAR BACKLASH cro
wn 1X natural gear
pin frequency GM
2 ion

The lateral bands slightly high at the gear frequency can be caused by eccentricity, backlash or
unparalleled axles, in such a way that one gear modulates the spinning frequency of the other.
The spacing of the lateral bands will indicate which gear has problems. When there is an
inappropriate backlash, the GMF and the gears natural frequency will get excited; both will
have lateral frequencies of 1X RPM. The GMF amplitudes will be reduced when the load on the
gears increases only when the backlash is the problem.
.

E. LACK OF ALIGNMENT 1X
BETWEEN GEARS cro
wn 1X
pin 1X 2X
2 ion

The lack of alignment between gears is almost always excited in the second harmonic wave and
greater gear frequencies or GMF, and they usually have lateral bands equivalent to the spinning
frequency. At times, they will only show low amplitudes at 1X GMF, but with greater levels at
2X and 1X GMF. It will be important to set the maximum frequency of monitoring for at least
2X GMF if the transducer has the capacity to check these frequencies.

1X RPM of a
F. BROKEN OR CRACKED damaged gear
TEETH tooth

A broken or cracked tooth will generate high amplitudes at 1X RPM in his gear, and also excite
the natural gear frequency with lateral bands at the spinning frequency. A better way to
observe damaged teeth is the wave shape. The time between impacts corresponds to the
spinning frequency of a gear that has one or more broken teeth. The wave amplitudes will be
greater.

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ELECTRIC PROBLEMS

DIAGRAM SPECTRUM

stator radial FL=3,600CPM

stator grooves reading 2X FL
rotor 1X
2X
rotor rods

ADDITIONAL COMMENTARIES

A. STATOR ECCENTRICITY, INTERFERING LAMINATION AND LOOSE STATOR

The stator problems generate high vibration when the frequency of the electric voltage doubles
(2XFL), as it can be seen in the diagram's spectrum. The eccentricity of the stator produces a
static air gap variable between the rotor and the stator that originated a high unidirectional
vibration. A loose leg or an uneven base can cause the stator to become eccentric. A
lamination interfering with the stator can heat up the stator, and the thermal change can cause
the rotor axle to bend. When the stator is loose, one should suspect lack of sturdiness.

radial reading
B. ECCENTRIC ROTOR
(VARIABLE AIR GAP)
Fp 1X 2FL Fp lateral bands around 2FL
L

The eccentric rotors produce a variable rotating air gap between the rotor and the stator that
produces pulsing vibration (normally between the frequency of 2FL and the closest harmonic
wave to the spinning frequency). In most cases, it will be necessary to take spectra of high
resolution and approach or "zoom into" this zone to separate the frequencies.

The eccentric rotors generate the frequency of 2FL surrounded by lateral bands equal to the
pole passing frequency, or Fp, as well as Fp lateral bands around the rotor spinning frequency.
The pole passage frequency could also appear in the spectrum's low frequency area. The most
common values for Fp vary from 20 to 120 CPM.

FL = electric line frequency

Fp = pole passing frequency = FS X P
NS = synchronous velocity = 120 X FL/P P = no. of poles
FS = movement frequency = NS - RPM

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ELECTRIC PROBLEMS (CONT.)

ADDITIONAL COMMENTARIES

Fp lateral bands around 1X, 2X, 3X...

C. ROTOR PROBLEMS 1X
2X 3X
Radial
reading

RBPF = passage frequency of rotor rods

RBPF
1X 2FL lateral bands
around RBPF
2X

Broken or cracked rods, interfering connection rings, rod looseness in the connection rings or
interfering lamination will cause a high vibration at 1X RPM hemmed with lateral bands
equivalent to the passing pole frequency Fp. Additionally, when there are cracked rods, lateral
bands will be formed near the first 4 harmonic spinning frequency waves.

When there is a problem with loose rods, a rotor rod (bar) passing frequency RBPF will be
created and it will have lateral bands whose value will be equivalent to double frequency (2FL).
it is possible that two RBPF harmonic wave bands appear also with lateral bands; in some
occasions, the frequency of 2 X RBPF is greater in amplitude than 1X RBPF.

The vibration due to electric problems will disappear when the motor energy is cut off.

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PULLEYS AND BANDS

DIAGRAM SPECTRUM
radial reading
with bands
x

1X driving pulley
harmonic

1X driven pulley
x wave
frequency
The band frequency is calculated the following way:
band freq. = 3.1416 X RPMpulley X pulley diameter
band longitude

toothed band freq. = RPMpulley X no. of pulley grooves

A. DAMAGED, LOOSE AND UNEVEN BANDS

The fundamental passage frequency of the bands and their harmonic waves is located in a lower
frequency range than any of the two, driven or driving, fundamental pole frequencies, as it can
be observed in the diagram spectrum. When they are damaged, loose or uneven, they will
cause 3 or 4 harmonic band passage frequencies, occasionally dominating harmonic waves of
2X.

The amplitudes are normally unstable and on occasions pulsing with the frequency of either of
the two poles. In case of the toothed belts, when there is unevenness between poles or they
are worn out, one will observe high amplitudes at the frequency of toothed belts.

1X of driven or
B. LACK OF ALIGNMENT BETWEEN PULLEYS driving pulley

axial reading

The lack of alignment in pulleys produces high axial vibration levels at 1X RPM in any of the two
poles. The amplitude will be greater in the equipment that is less rigid; the amplitude will also
depend on the place where the measurement is taken. At times the high axial vibration
frequency in a motor will be the ventilator frequency.

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axial reading
1X
C. BAND RESONANCE band resonance
x
x

The band resonance can occasionally cause high vibration levels when the natural frequency of
the bands coincides with the spinning frequency of either of the two poles. The natural band
frequency can be modified changing their tension, or changing their longitude. This natural
frequency could be measured with the transducer connected to the support while tensing and
releasing one of the bands.

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RHYTHMIC VIBRATION

SPECTRUM
DIA
(F
2-
F1 pulsing vibration

Frequency difference

F1 F2
= rhythmic frequency
zoomed spectrum
The minimum vibration The maximum vibration occurs
occurs when the when both frequencies are in
frequencies are 180° phase.
outside of the phase.

The vibration caused by the rhythmic frequency is the result of two vibration frequencies close
to each other; they enter and exit the rhythmic synchrony. The spectrum on the upper part of
the diagram shows the pulsing behavior or a vibration peak close to both frequencies.

In the zoomed spectrum in the lower part of the diagram, one could observe both vibration
frequencies, one close to the other. The difference in frequency between these two vibrations
will determine the rhythm with which the vibration levels will move upward or downward.

Normally, this rhythmic frequency will not appear in the spectrum because it has very small
values that range from 5 to 100 RPM.

The maximum vibration values will occur when both frequencies are in phase, and vice-versa,
the lowest vibration levels will be obtained when both frequencies are 180° outside of the
phase.

This type of problems will usually occur when two machines with similar spinning frequency are
mounted on the same base and both have a high residual unbalance. The values of the
unbalances will add up and subtract themselves, causing rhythmic vibration.

Vibration Analysis Manual Page 143 of 143