Causes of Vibration in Mechanical Equipment

The vibration peak measured at point B occurs in time after the vibration peak measured at point A. The
vibration at point A is said to lead to the vibration at point B.

The phase relationship between acceleration, velocity and displacement

1. Imbalance: Imbalance occurs when the center of mass of a rotating component, such as a rotor or fan
blade, is not aligned with the axis of rotation. Imbalance can occur due to manufacturing defects, uneven
material distribution, or changes in the mass distribution over time, such as material build up or erosion.
This results in centrifugal forces during rotation. The resulting vibration occurs typically at the rotational
speed or its harmonics.

2. Misalignment: Misalignment refers to the condition where the rotational axes of two or more
components do not align properly. It can occur in couplings, belts, gears, or shafts. Misalignment can be
angular, parallel, or a combination of both. Vibration due to misalignment arises from the uneven
distribution of forces and moments on the connected components. It can cause excessive wear, fatigue, and
premature failure of parts.
3. Loose or worn-out parts: Vibrations caused by loose or worn-out parts are often characterized by high-
frequency oscillations. Loose bolts, fasteners, or connections can result in relative movements between
components, leading to vibrations. Worn-out bearings, gears, or belts can exhibit play or backlash,
generating vibrations as they transmit forces. Over time, vibration from loose or worn-out parts can further
damage adjacent components, resulting in a cascade of failures.
4. Resonance: Resonance occurs when the natural frequency of a system matches the excitation frequency.
This can cause significant amplification of vibrations and can be detrimental to the equipment's integrity.
Resonance can be caused by a variety of factors, including stiffness, mass, and damping characteristics of
the system. It is crucial to avoid operating equipment near its natural frequencies or take appropriate
measures, such as adding dampers or changing the system's stiffness, to mitigate resonance effects.
5. Mechanical looseness: Mechanical looseness can occur in various forms, such as excessive clearance
between components, worn-out joints, or weak supports. Vibrations caused by mechanical looseness are
typically broad-spectrum, covering a wide range of frequencies. The amplitude of vibrations may change
as the equipment operates or experiences different loads. Detecting and rectifying mechanical looseness is
essential to prevent further damage and maintain equipment reliability.

6. Bent shaft or shaft runout: A bent shaft refers to a shaft that has a curvature or deviation from its
straight axis of rotation. Shaft runout refers to the eccentricity or wobbling of the shaft in its rotational path.
These conditions can arise from manufacturing defects, improper handling, or excessive loads. Bent shafts
or shaft runout can lead to vibrations and affect the performance and life of rotating equipment.
https://www.youtube.com/watch?v=51Pr4vXwbCo
7. Bearing Issues: Bearings are crucial components that support the rotor and enable smooth rotation.
Bearing defects such as wear, misalignment, or insufficient lubrication can lead to increased friction, heat
generation, and vibration.
Ball Pass Frequency Outer Race (BPFO):
BPFO or outer race failing frequency
corresponds physically to the number of
balls or rollers that pass through a given
point of the outer race each time the shaft
makes a complete turn.

Ball Pass Frequency Inner Race (BPFI): BPFI

or inner race failing frequency corresponds
physically to the number of balls or rollers
that pass through a given point of the inner
track each time the shaft makes a complete
turn.

Ball Spin Frequency (BSF): BSF or rolling

element failing frequency corresponds
physically to the number of turns that a
bearing ball or roller makes each time the
shaft makes a complete turn.

Fundamental Train Frequency (FTF): FTF or

cage failing frequency corresponds
physically to the number of turns the
bearing cage makes each time the shaft
makes a complete turn.

By calculating these fault frequencies, you

can analyze the vibration spectrum and look
for peaks at these frequencies, which may
indicate bearing faults. It’s essential to
consider that these calculations are for ideal
conditions, and real-world factors like
manufacturing tolerances, wear, and
lubrication can affect the actual fault
frequencies. Thus, it is good to set a baseline
 where you produce a measurement set in
close to optimal conditions and observe
historical data over a long period of time.

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8. Cavitation: Cavitation occurs when the pressure of a fluid drops below its vapor pressure, causing the
formation and collapse of vapor bubbles. The collapsing bubbles can create shockwaves and induce high-
frequency vibrations. It commonly affects pumps and hydraulic systems.
9. Gear meshing issues: Gear misalignment, tooth wear, or other gear meshing problems can generate
vibrations. These vibrations are typically characterized by distinct frequencies related to the gear tooth
engagement.
10. Electric motor issues: Faults in electric motors, such as rotor imbalances, misalignment, bearing
problems, or electrical problems like unbalanced voltages, can lead to excessive vibrations. These issues can
cause increased noise, reduced motor efficiency, and even motor failure if not addressed promptly.
11. External forces: External forces can also contribute to vibrations in mechanical equipment. Examples
include unbalanced loads on rotating machinery, vibrations transmitted from nearby equipment or structures,
or environmental factors like earthquakes or strong winds. These external forces can introduce additional
dynamic loads and excite vibration modes in the equipment, potentially leading to increased stress and
fatigue.
Multiple factors can often contribute simultaneously. Identifying the specific causes requires
thorough inspection, analysis, and sometimes specialized diagnostic tools. Regular maintenance, monitoring,
and addressing these causes promptly can help prevent excessive vibration and ensure the optimal
performance and longevity of mechanical equipment.
It's important to note that the severity of vibrations can vary depending on factors such as the
equipment's design, operating conditions, maintenance practices, and the skill of the operator or maintenance
personnel. Regular inspection, monitoring, and maintenance programs are crucial to identify and address the
causes of vibration, ensuring safe and reliable operation of mechanical equipment.
Using spectrum analysis and frequency domain analysis to identify and diagnose various issues related
to vibration
1. Collect Vibration Data: To perform spectrum analysis, you need to collect vibration data using
appropriate sensors or accelerometers. These sensors measure the vibration amplitudes at different
frequencies and provide time-domain data.
2. Convert Time Domain to Frequency Domain: The collected time-domain data needs to be converted to
the frequency domain using techniques such as Fourier Transform. This conversion helps analyze the
vibration components at different frequencies.

3. Power Spectrum: The resulting frequency domain data is represented as a power spectrum, which shows
the power distribution across different frequencies. The power spectrum is commonly displayed as a graph
with frequency on the x-axis and amplitude on the y-axis.
4. Identify Dominant Frequencies: Analyze the power spectrum to identify dominant frequencies or peaks.
These peaks indicate the presence of specific frequencies associated with the vibration sources. By
comparing these peaks with known frequencies related to various issues, you can narrow down the potential
causes.
Example:
Let's say you are analysing the vibration of a motor. After converting the time-domain data to the
frequency domain, you observe a peak at a frequency of 50 Hz in the power spectrum. This could indicate a
misalignment issue, as misaligned components often generate vibration at specific frequencies.
To justify this, you can compare the observed frequency with the theoretical values or known
frequencies related to misalignment issues in motors. If the motor's design or previous experience suggests
that misalignment can cause vibration at 50 Hz, it strengthens the possibility of misalignment being the
cause in this case.
5. Harmonic Frequencies: In addition to dominant frequencies, it's important to look for harmonic
frequencies. Harmonics are integer multiples of the fundamental frequency and can indicate issues such as
imbalance or gear meshing problems. Analysing the presence and intensity of harmonic frequencies can
provide valuable insights into the underlying causes.

Example
 Suppose you are analysing the vibration of a rotating fan, and you observe peaks at 100 Hz, 200 Hz,
and 300 Hz in the power spectrum. These are harmonic frequencies of the fundamental frequency, which is
likely associated with the fan's rotational speed. The presence of harmonic frequencies suggests potential
issues such as imbalance or gear meshing problems, as these can generate vibrations at harmonics of the
fundamental frequency.
To justify this, you can compare the observed harmonic frequencies with known frequencies related
to imbalance or gear meshing issues in fan systems. If the observed harmonic frequencies align with the
expected values, it supports the hypothesis of imbalance or gear meshing problems as the potential causes.
6. Diagnostic Guidelines and Standards: It's important to consult diagnostic guidelines, standards, or
vibration databases specific to your industry or equipment type. These references provide valuable
information on expected frequencies and vibration signatures associated with different issues. By comparing
your measured frequencies with these references, you can gain further insights into the potential causes.
Example
Suppose you are analysing the vibration of a centrifugal pump, and you observe a peak at 1500 Hz in
the power spectrum. Consulting the pump manufacturer's diagnostic guidelines, you find that this frequency
is associated with cavitation issues. Cavitation can generate high-frequency vibrations due to the collapsing
vapor bubbles.
To justify this, you can compare the observed frequency with the known frequencies related to
cavitation issues in centrifugal pumps. If the observed frequency aligns with the expected values, it
strengthens the possibility of cavitation as the cause.

7. Frequency Resolution: The frequency resolution of spectrum analysis refers to the smallest frequency
increment that can be distinguished in the power spectrum. It is determined by the number of data points and
the duration of the time-domain signal. A higher number of data points or a longer signal duration improves
the frequency resolution, allowing for more accurate identification of specific frequencies. A resolution of
0.1 Hz means that the frequency response variations at frequency intervals at or below 0.1 Hz are not
resolved.

8. Frequency Ranges: Different vibration issues exhibit characteristic frequency ranges. For example,
imbalance and misalignment issues often result in low-frequency vibrations, typically below 1000 Hz. On
the other hand, gear meshing problems or bearing faults can generate vibrations in higher frequency ranges,
extending into the kilohertz range. Understanding the expected frequency ranges associated with specific
issues can help guide the analysis and interpretation of the power spectrum.
9. Sidebands: Sidebands are additional frequency components that appear alongside the dominant
frequencies in the power spectrum. They are often indicative of modulation effects caused by faults such as
gear damage, bearing defects, or looseness. Sidebands appear as pairs of frequencies on either side of the
dominant frequency, typically at equal intervals.

Example:
Suppose you are analysing the vibration of a gearbox, and you observe sidebands around the
dominant frequency of 1000 Hz in the power spectrum. The presence of sidebands suggests potential gear
damage as a fault condition. Gear damage can cause amplitude modulation of the vibration signal, resulting
in sidebands at frequencies related to the gear's rotational speed.
To justify this, you can compare the observed sideband frequencies and their spacing with known
values associated with gear damage. If the observed sidebands align with the expected values, it supports the
hypothesis of gear damage as the potential cause.
10. Order Analysis: Order analysis is a technique for analysing noise and vibration signals in rotating or
reciprocating machinery such as engines, compressors, turbines, and pumps. The first order refers to the
speed at which the machine rotates. Each order thereafter is a corresponding multiple of the rotational speed.
Order analysis helps identify specific components or events related to the rotational cycle, such as gear teeth,
fan blades, or contact events.

Example:
Suppose you are analysing the vibration of a compressor, and you notice significant peaks at the 6th
order (6× rotational speed) in the power spectrum. This indicates a potential issue related to the compressor's
rotating components, such as imbalanced impellers or worn-out compressor blades. The 6th order
corresponds to the characteristic frequency associated with the specific component.
 To justify this, you can consult the equipment manufacturer's documentation or reference materials
that provide order analysis guidelines for compressors. If the observed orders align with the expected values,
it strengthens the possibility of imbalanced impellers or worn-out compressor blades as the cause.
11. Trend Analysis: Spectrum analysis can be performed over time to monitor changes in vibration
characteristics. By periodically collecting and analyzing vibration data, trends in the power spectrum can be
observed. Sudden shifts, increasing amplitudes, or the appearance of new frequencies can indicate the
development of faults or worsening conditions.
Example:
Suppose you are monitoring the vibration of a motor over several months, and you notice a gradual
increase in the amplitude of a specific frequency peak in the power spectrum. This trend suggests the
potential development of a fault, such as bearing wear or deterioration. As the bearing condition worsens,
the vibration amplitude at the corresponding frequency increases over time.
To justify this, you can compare the observed trend with historical data, maintenance records, or
vibration severity guidelines for the motor. If the trend aligns with the expected behavior associated with
bearing wear, it supports the hypothesis of bearing wear as the potential cause.
Remember that spectrum analysis and frequency domain analysis provide valuable insights, but they
should be used in conjunction with other diagnostic techniques such as visual inspection, dynamic
balancing, and alignment checks to obtain a comprehensive understanding of the vibration-related issues
in mechanical equipment.
These analyses provide valuable insights into the underlying causes, enabling timely maintenance,
repair, or replacement actions to ensure the reliability and performance of the machinery.

Causes of Vibrations in Electric Motors

1. Imbalance: Imbalance occurs when the mass distribution of the motor's rotating components, such as the
rotor, is uneven. This imbalance can cause significant vibration during motor operation. Imbalance can be
attributed to manufacturing defects, wear and tear, or improper maintenance.
Justification: If the voltage supplied to the motor is not stable, it can lead to fluctuations in the motor's
rotational speed. These speed variations can further amplify the effects of imbalance, resulting in increased
vibration. As the motor operates at different speeds due to voltage fluctuations, the imbalance-induced
vibration becomes more pronounced.
2. Resonance: Resonance can occur when the natural frequency of a motor or its connected mechanical
system matches the excitation frequency generated by the motor. When resonance occurs, even small
imbalances or external disturbances can cause significant vibration amplitudes.
Justification: Variations in the supplied voltage can affect the motor's operating frequency. If the voltage
fluctuates around the motor's natural frequency or certain harmonic frequencies, it can create resonance
conditions. The resonance amplifies the vibration levels, leading to excessive vibrations in the mechanical
system connected to the motor.
3. Misalignment: Misalignment refers to the improper alignment of the motor's shaft with the driven
equipment's shaft. It can occur due to installation errors, thermal expansion, or external forces.
Misalignment can cause uneven loading, increased friction, and vibration in the motor and the connected
equipment.
Justification: Voltage variations can influence the motor's torque and speed characteristics. If the voltage
fluctuates significantly, it can affect the motor's performance, leading to uneven loading and torque
transmission. This uneven loading caused by voltage variations can exacerbate misalignment-related
vibration and increase the overall vibration levels in the mechanical system.
4. Bearing Issues: Bearings are crucial components in electric motors that support the rotor and enable
smooth rotation. Bearing defects such as wear, misalignment, or insufficient lubrication can lead to
increased friction, heat generation, and vibration.
Justification: Voltage variations can affect the motor's power output, which indirectly affects the load on the
bearings. If the voltage drops below the motor's rated voltage, the motor may not provide sufficient power to
overcome the load demands. This can result in increased bearing friction and vibration due to inadequate
lubrication, wear, or misalignment, exacerbating the vibration levels in the equipment.
5. Residual Unbalance: Even with well-balanced rotors, there can be residual unbalance due to
manufacturing tolerances. This residual unbalance can cause vibration during motor operation.
Justification: Voltage variations can impact the motor's operating speed, and when the motor operates at
different speeds, the effects of residual unbalance can become more noticeable. If the voltage fluctuates, the
motor's speed changes, causing the unbalance-induced vibration to vary in intensity, resulting in increased
overall vibration levels.
Voltage Variations on Motor Vibration: Voltage variations can have a direct impact on the motor's
electrical and mechanical characteristics. The justifications provided above are based on the understanding
that voltage variations affect the motor's speed, torque, and power output, which, in turn, affect the
mechanical forces and loads experienced by the motor's components. These variations can exacerbate
existing vibration sources or introduce new sources of vibration, leading to increased vibration levels in the
connected mechanical equipment.
unequal magnetic forces acting on the rotor or the stator. These unequal magnetic forces may be due to:
• Open or short windings of rotor or stator • Broken rotor bar • Unbalanced phases • Unequal air gaps.
Generally, the vibration pattern emerging due to the above-mentioned electrical problems will be at 1× RPM
and will thus appear similar to unbalance. A customary technique to identify these conditions is to keep the
analyzer capturing the FFT spectrum in the live mode and then switching off the electrical power. If the peak
disappears instantly, the source is electrical in nature. On the other hand, if there is gradual decrease in the
1× amplitude it is more likely to be a mechanical problem. However, this technique requires caution. If there
is a time lag in the analyzer itself, it may delay the drop in vibration amplitude. It is also possible that a
resonance frequency may drop quickly as the speed changes.
 It's important to note that voltage variations are not the only cause of motor-induced vibration. Other
factors such as mechanical wear, unbalanced loads, resonance, and structural issues can also contribute to
vibration. Therefore, a comprehensive analysis considering multiple factors is necessary to accurately
diagnose and mitigate vibration issues in mechanical equipment caused by electric motors.

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