In Collaboration with

APSSDC

SEMAPI INSTITUTE
TRAINING ON
VIBRATION MONITORING &
FAULT DIAGNOSIS

A BASIC VIBRATION ANALYSIS COURSE FOR MECHANICAL

GRADUATES 1
 Vibration Monitoring & Fault Diagnosis of
Machinery
1. Condition Monitoring As an Aid For Predictive
Maintenance

2. Vibration Monitoring

3. Fault Diagnosis of Machinery

4. Various Types of Defects and Nature of

Vibration Signatures

2
 Predictive Maintenance

Operational Phase
of the Machine

Time

Vibration Measurement
Monitoring of Running Condition
(Deterioration)
Shut Down Level
Vibration level

Alarm Level

Lead
Time

Running Time
 Predictive Maintenance

Operational Phase Operational Phase of the

of the Machine Machine

Time

Vibration Measurement

Maintenance
Running Condition Vs Vibration

Increased vibration levels indicate:

•Increased Wear of Mechanical Components

•Reduction in the Available Power due to Friction Losses
•Fatigue in the Components due to Alternating Stresses
•Distortions in the Structural Members

6
 Parameters Which Can Represent
Running Condition of a Machine
• Temperature • Level
• Vibration • Leak
• Noise • Flow
• Efficiency • Ultrasonic Emission
• Pressure • Acoustic Emission
• Speed • Appearance
• Current • Air gap
• Carbon Brushes • Power Circuit Faults in Motors
• Corrosion • Wear Debries
• Power Performance • Oil Characteristics

7
Benefits of Condition Monitoring
• Cost as well as value Effective
• Increased Reliability
• Decrease in Sudden Breakdowns
• Reduction in Duration of Maintenance
• Avoids Storage of Large Number of Spares
• Avoids Replacement of Good Components
• Increases the Availability of Machinery
• Avoids Catastrophic Failures

8
Common Causes Of Vibration

• Design & Manufacturing Errors

• Dynamic Unbalance
• Installation & Alignment Errors
• Mechanical Looseness
• Resonance
• Bearing Defects
• Gear Defects
• Electrical Defects
• Irregularities in the Flow

9
Generation of Vibration in
Machinery

Rotor

10
 Generation of Vibration in
Machinery
Resulting Vibration

Forces
Applied to the
Bearings Rotor

Bearing
Pedastal

Vibration = Rotor Force x Mobility of the Bearing

And,
Mobility=Vib/Force 11
 Basic Characteristics of Vibration

T
Amplitude

Peak to Peak
00 1800 3600 Time Amplitude

Frequency = 1/T
12
 DISPLACEMENT, VELOCITY
AND ACCELERATION

Vibrating Object:

13
DISPLACEMENT, VELOCITY
AND ACCELERATION
DISPLACEMENT:

VELOITY:

14
DISPLACEMENT, VELOCITY
AND ACCELERATION
ACCLERATION:

Displacement = X
Velocity = V = (2f) X
Acceleration = A = (2f)2 X
Frequency = f

15
 Sinusoidal Vibration waves
Generated By Various Defects
Defect 1 (F1)

Defect 2 (F2)

Defect 3 (F3)

Defect 4 (F4)

16
Overall Vibration Waveform
(Random Wave)

Time RMS
Amplitude

17
 ISO 10816 - Vibration Severity
Chart
Vibration Class 1 Class 2 Class 3 Class 4
Amplitude
RMS, mm/s
0.28
0.45
0.71
1.12
1.8
2.8
4.5
7.1
11.2
18.0
28.0
45.0

18
Constituent Sinusoidal Vibration
waves (Time Domain)
Defect 1 (F1)

Defect 2 (F2)

Defect 3 (F3)

Defect 4 (F4)

19
 Vibration Signature
Vibration Amplitude

f1 f2 f3 f4
Frequency

20
 Effect of Unbalance

R
C.G

Rotational
Axis
 Effect of Unbalance

Unbalance Mass, m

Principle
Axis of
Inertia R
C.G

Rotational
Axis
 Effect of Unbalance

Unbalance Mass, m

Principle
Axis of
Inertia R
C.G

Rotational
Axis

Centrifugal (Unbalance) Force, F = m*ω2 *R

Vibration Generated by
Unbalance

Vibration Amplitude
ω

R
F

Time
 Typical Vibration Signature of
Unbalance

100
Amplitude, VdB

95

90

85

80
0 200 400 600 800 1000
Frequency, Hz
25
Misalignment

26
 Parallel Misalignment

Vibration Frequency = 1× Shaft Rotational Speed

Direction of Vibration = Radial

27
 Angular Misalignment
(Bent Shaft)
Axial Force Axial Force

α
Force due to Angular
Misalignment

Frequency = 1 X Shaft Rotational Speed

= 2 X Shaft Rotational Speed

Direction = Radial & Axial

28
Factors Influencing Misalignment

1. Soft Foot

2. Piping Strain

3. Induced Frame Distortion

4. Excessive Bearing Clearance

5. Shaft Rules

29
 Typical Vibration Signature of
Misalignment

110
Amplitude, VdB

Misalignment
105

100

95

90
0 100 200 300 400 500
Frequency, Hz
30
Mechanical Looseness

31
Truncated Vibration Waveform

32
Truncated Vibration Waveform

33
 Predominant Vibration
Frequencies
(Mechanical Looseness)
Bearing Pedestals etc. (Stationary Parts) 1 × RPM
2 × RPM
3 × RPM

Impellers etc. (Rotating Parts) 1 × RPM

Harmonics of RPM

Direction of Vibration Vertical

34
 Typical Vibration Signature of
Mechanical Looseness
Mechanical Looseness
110
Amplitude, VdB

105

100

95

90
0 100 200 300 400 500
Frequency, Hz
35
Typical Vibration Signature of
Mechanical Looseness

Pitch Diameter Pd
Ball
Diameter Bd

Contact
angle
=ɸ ɸ
Nb = Number of Balls
36
 Rolling Element Bearing
Defect Frequencies:
Nb  RPM Bd Cos 
Inner Race, BPFI = 1+
120 Pd

Outer Race, BPFO = Nb  RPM Bd

120
1- Pd Cos 
Bd 2
Pd  RPM
(
(
Cos 
Ball/Roller, BSF = 1- Pd
Bd  120

Cage, FTF = RPM 1 - Bd Cos 

120 Pd

Direction Axial & Radial

37
 Rolling Element Bearing
If Bearing Dimensions are unknown, But No. of
Balls/Rollers are known, then
Approximate Defect Frequencies:

RPM Nb
Inner Race, BPFI  + 1.2
60 2

Outer Race, BPFO  RPM Nb

- 1.2
60 2

RPM Nb 1.2
Ball/Roller, BSF  -
120 2 Nb

RPM 1
Cage, FTF  1.2
-
60 2 Nb

38
 Rolling Element Bearing
If Bearing Dimensions are unknown, But No. of
Balls/Rollers are known, then
Approximate Defect Frequencies:

RPM X Nb
Inner Race, BPFI  0.6
60

RPM X Nb
Outer Race, BPFO  0.4
60

RPM
Cage, FTF 
60
Oil Whirl in Journal Bearings

Journal Bearing

Shaft

40
Oil Whirl in Journal Bearings

Journal Bearing

Shaft

Fluid Flow

41
 Oil Whirl in Journal Bearings

Low Pressure Fluid

Journal Bearing

Shaft

High Pressure Fluid Fluid Flow

42
 Oil Whirl in Journal Bearings

Whirl Low Pressure Fluid

Journal Bearing
Resultant Pressure

Destabilising Force Shaft

High Pressure Fluid Fluid Flow

Support Force

43
Factors Causing Oil Whirl in
Journal bearings
• Excessive Bearing wear or Clearance

• Light Dynamic and Pre Load Forces

• Changes in lube oil properties

• Pressure

• Temperature

• Density

• Viscosity
Nature of Vibration Generated
by Oil whirl
Self Excited Vibration

Frequency 0.42 to 0.48 x RPM

Direction Radial
 Gear Defects

T1

N1

Meshing 1

T2

46
 Gear Defects

T1 T4
N1

Meshing 2

Meshing 1

N2
T2

T3

47
 Gear Defects

T1 T4
N1 N3

Meshing 2

N4
Meshing 3
Meshing 1

N2
T2

T3

48
 Gear Defects

T1 T4
N1 N3

N4
T5XN3=T6XN4
T3XN2=T4XN3
T1XN1=T2XN2 N2
T2

T3

49
Possible Defects in Gear Trains
• Overloading

• Manufacturing errors in gear profile

• Meshing (Transmission) Errors

• Gear Tooth Wear

• Unbalance /Misalignment in gear wheels

• Excessive Tooth Load

• Cracked, chipped or Broken Gear Teeth

• Eccentricity & Backlash

• Hunting Tooth Problem

 Typical Vibration Signature of
Gear Meshing
110
Gear Meshing Frequencies

100
Amplitude, VdB

90

80

70

60
0 1 2 3 4 5
Frequency, KHz
51
 Flow Induced Vibration
1. Re – Circulation

2. Flow Turbulence

3. Hydraulic & Aerodynamic Forces

4. Choking

5. Cavitation and Starvation

6. Surge
 Defect Frequencies
BPF = Blade/Vane pass frequency
BRF = Blade/Vane rate frequency
(K = H.C.F of # vanes in impeller & diffuser)

No. of Vanes  Impeller RPM

BPF =
60

No. of Impeller Vanes  No. of Diffuser vanes  RPM

BPF = 60  K
 Belt Drive Problems

1. Worn, Loose or Mismatched Belts

2. Belt Sheave Misalignment

3. Eccentric Sheaves

4. Belt Resonance

5. Loose Pulley or Fan Hub

Belt Vibration Frequency, BF:
  Pulley RPM  Pulley Pitch Dia.
Belt Length

Direction of Vibration: Perpendicular to the Belt

 Predominant Defect Frequencies
In Belt Drives

Belt/Sheave Misalignment = 1 X Driver or Driven RPM

Eccentric Sheaves = 1 X RPM of Eccentric Sheave

Worn, Loose or Mismatched Belts = BF, 1 X Driver RPM and 1 X Driven RPM

Belt Resonance = 1 X RPM, Belt Nat. Freq.

Electrical Machines

Rotor ( Armature)

CL of Rotor
 Electrical Machines
S
N
S Rotor ( Armature)
N

CL of Stator

CL of Rotor

Stator
 Electrical Machines
S
N Air gap between
Rotor and Stator
S
Rotor ( Armature)
N

CL of Stator

CL of Rotor

Stator
 Line Frequency

Pole Passing Frequency

60
 Predominant Defect Frequencies
In Electrical Machines
• Eccentric Rotor 1 X RPM (2XLF SB) Axial & Radial

• Loose Stator Lamination 2 X Line Frequency Axial & Radial

• Broken Rotor Bar 1 X RPM Axial & Radial

• Phase or Coil Unbalance 2 X Line Frequency Axial & Radial

• Pole Passing 2 X Line Frequency Axial & Radial

Vibration Frequencies Related
to Machinery Defects
Vibration Frequencies Related
to Machinery Defects