1.

MAINTENANCE PHILOSOPHY

 Breakdown Maintenance

 Preventive Maintenance

 Predictive Maintenance

2. CONDITION MONITORING PROGRAM

 Condition Monitoring Tools

 Main Requirement to Start Condition Monitoring Program

 Methodology
 Purpose of Parameters Measurement
3. VIBRATION MEASUREMENT

 Introduction

 Main Causes of Vibration

 Data Acquisition
 Vibration Parameters
 Time Wave Form Signal
 Use of Vibration Frequency
 Use of Vibration Amplitude
4. VIBRATION TRANSDUCER
 Vibration Transducers

 Velocity Pickup

 Accelerometers

 Transducer Selection

 Vibration Parameters

5. VIBRATION ANALYSIS

 Data Analysis
 General Analysis Procedure

 Most Important point in analysis

Breakdown Maintenance
Machines run without maintenance until they breakdown ( run to fail )

Q. When do we use breakdown maintenance ?

A. In industries using relatively inexpensive machinery and having 100 % stand –

by process facilities . The production can be put back into service .
Q . What is the advantage of this maintenance philosophy ?

A. It saves the high cost of periodic maintenance or condition monitoring, if the

repair / replacements are of low cost.

Q . What are the disadvantages of this maintenance philosophy ?

A. High spare parts inventory ( stocking )

• High machine down time

• Low availability of equipment
 Preventive Maintenance

Maintenance is planned at fixed intervals , based on the minimum expected time

lapse between breakdowns of the involved components . This minimum time lapse
is based on experience . Preventive maintenance techniques are widely used .

Q. When do we use preventive maintenance ?

A. In industries using relatively expensive machinery and in process plants with

only partial stand – by components and no permissible out – of – use
possibilities.
Q. What is the advantage of this maintenance philosophy ?

A. It should eliminate unscheduled breakdowns and sudden components failure.

Q. What are the disadvantages of this maintenance philosophy ?

A. High maintenance cost .

- The need for scheduled shutdowns in certain cases .
Predictive Maintenance
The equipment are maintained , only at certain per-determined condition/
performance tendency. The condition / performance are measured, either
continuously or at intervals. By following the trends of the measured
parameters, potential failures can be detected and the overhaul/repair can be
planned. The concept of On – Condition Maintenance is becoming increasingly
common, especially for expensive equipment. Protection against suddenly
accelerated failure can only be obtained by frequent or continuous Condition
Monitoring .
Q. When Do We Use Predictive Maintenance ?
A. In industries using expensive machinery and need to reduce equipment
maintenance cost and down time.

Q. What Are The Advantages of Predictive Maintenance ?

A. The interval between repairs / overhauls can be extended, thus

reducing the overall maintenance cost.
Q . What Are The Disadvantages of Predictive Maintenance ?
A . High initial cost for this system.

- It requires highly skilled resources.

N.B:

High initial cost can be avoided through rented services , until the amount of
workload and the in house resources are adequate .
Condition Monitoring Tools

- Vibration and Flow Pulsation Spectrum Analysis

Changes in vibration levels, detected by repetitive good diagnostic, indicate a
problem, which can be solved before a damage would happen

- Lube Oil Analysis.

Changes in lube oil parameters, reveals information regarding the condition of

the equipment. This is similar to human blood analysis, which reflects human
body system’s function

- Infrared Thermal Imaging

Unbalanced thermal condition of components reveals, and locates a potential

problem. This is an advanced technology of condition monitoring and is used
for rotating – as well as stationary parts.
 Main Requirement to Start Condition Monitoring Program

- Select suitable monitoring parameters

□ Vibration , flow pulsation

□ Lubricant oil analysis
□ Infrared thermal image

- Qualified engineers, who have the following qualification :

□ On-job training on the condition monitoring policy and data analysis

□ Good understand of the equipment components, theory of
machine and operating condition.
□ Good background of maintenance activity.
□ Ability to help maintenance staff by recommending practical
correction measures .
- Measurement Instruments
Methodology

- Identify the critical machine to be included in the program.

- Establish acceptable levels of measured parameters.

- Review each equipment operating condition and normal condition.
- Select suitable measurement locations.
- Select the time interval for periodic monitoring survey

- Visually inspect the machine and its attachments / piping. Check all
holding bolts, any cracks, corrosion, and loose parts.
- Check noise levels and its relation with operating condition.
 Purpose of parameters Measurement
( a ) Routine periodic checks

A periodic check allows detecting the problems in their early formation, so that
repair can be scheduled.

( b ) Baseline measurements

This is the measurement, made on a normal operating machine , running under

normal operating conditions in its final installed configuration . Normal vibration
levels under these conditions serve as a “ baseline “ to which we can compare
subsequent measurements.

( c ) Before and after overhaul ( repair ) checks

Measurement before an overhaul can indicate the parts of machines, which

require repair . After-overhaul measurements are to verify if the problems have
been successfully corrected .
( d ) Machine troubleshooting

Measurements are frequently made to pinpoint the cause of excessive defect in a

machine. Also, on some machine tools for example, the purpose of vibration
measurements and analysis may be to determine the cause of poor finish, chatter
marks or out-of –tolerance arts.

Introduction

Vibration measurements must be applied systematically and not only , when

trouble is evident.

The engineer should make an overall evaluation of the need for measurements
in relation to criticality , presently available personnel, and his company’s
maintenance philosophy .
Q. When do vibrations happen ?
A. Vibrations happen when rotating parts oscillate with relevance to the
stationary parts in an equipment . The effects of stationary parts are known
as equipment mobility ( this can dampen or amplify the vibration of rotating
parts )

Q . Are there equipment without vibration ?

A. Any equipment has normally a certain vibration level, related to dynamic

effects from tolerances and clearances between rotating and stationary
parts, unbalanced forces and bearings defect. There for, our concern is
always the change in vibration levels.
Main Causes of Vibration

•Misalignment of connected shafts or between a shaft and its bearings.

•Misalignment between flanges.
•Unbalance of rotating parts.
•Bent shaft.
•Broken or worn gear teeth.
•Anti-friction bearing wear.
•Belts drive problems.
•Hydraulic problems.
•Looseness parts.
•Oil whirl.
•Resonance.
•Electromagnetic problems.
 Vibration Analysis

Vibration analysis is a two-step process :

•Data ACQUISITION
•Data INTERPRETATION

Its purpose is to determine the mechanical conditions of a machine, and

pinpoint any specific mechanical or operational defects.

Data Acquisition

The right data must be acquired under the right conditions to correctly interpret a
machine’s condition.
Data Acquisition Requires the Following Steps :

Determine the machine’s design and operating characteristics, i.e. the running
speed, the bearings’ types , gears, etc.
Review the maintenance history and problems .
Check the physical conditions ( structure looseness, noise, etc) .
Record the operating conditions, i.e. temperature, load , speed, etc .
Determine the purpose of the measurement as stated above .
Select the measurement parameter, i.e. displacement, velocity , acceleration, and
phase .
Select the measurement instruments, i.e. vibration analyzers, tape recorder, etc.
and the measurement transducers, i.e. accelerometer, non-contact pickup , etc.
Determine the transducer measurement positions and directions .
Determine the specific type of data required, i.e. amplitude vs. frequency,
amplitude vs. time, and phase .
Determine the most efficient order for taking the measurements, watch for
unexpected results, and be prepared to take additional data, review the data to
ensure its validity and adequacy .
Vibration Parameters
As mentioned earlier, the measurable parameters to be considered are :

Frequency ( CPM, Order , HZ )

Amplitude ( Displacement, Velocity , Acceleration, Pressure unit )
Phase

Data Analysis
Data analysis is difficult, because some frequencies are unacceptable. Other
frequencies cannot be present above some amplitude, and there is some
disagreement on the acceptable amplitude of these frequencies. Some problems
are identified based on the presence of more than one frequency. Some problems
generate wide – band noise. The time signal is required to identify pulses, type of
modulation, amplitude of each cycle, phase relationships, truncation. It is difficult
for a person to remember, recall, and apply the information required for analysis.
Moreover, it may take months or years to acquire the required depth, and
proficiency. This makes a strong case for expert diagnostics with computers.
Some frequencies are not acceptable at any level within prescribed calibration
levels. They include roller bearing frequencies, harmonics, sum and difference
frequencies. Also, fractional ( ½ , 1-1/2 … ) rotor speed and gear mesh
frequencies modulation by multiples of gear speed should not be present. Electric
motor speed, modulation by slip frequency times the number of poles Indicates
broken rotor bars and normally not be present. Except for fluid film bearings,
harmonics of rotor speed should not be present .
Frequencies acceptable below some level include : rotating speed, gear mesh,
blade pass, vane pass, etc. four or five harmonics of rotor speed in fluid film
bearings is acceptable. However, if the number of harmonics or the amplitude
increases, a problem is present .

Misalignment is normally characterized by distinctive first three harmonics of

speed. Misalignment gears can also generate the first three harmonics of gear
mesh frequency. Several harmonics of rotor speed indicates looseness.
Broadband noise or noise skirts at the base of the spectral lines normally means
looseness. However, wide – band noise around vane pass frequency indicates
cavitation. Fractional shaft speed also indicates looseness.
General Analysis Procedure

Most important point in analysis

 Review with maintenance staff, equipment maintenance history.

• Review with operator, change in operating condition before and after vibration
levels change.
 Should depend on frequency, amplitude analysis
• Some equipment have non harmonics ( roller bearing frequency ) have
amplitude value lower than at running speed but its mean serious problem
should take into consideration.
• The rapid change in vibration amplitude in spectrum is usually near the part of
the equipment, which is about to fail.

• Visual inspection for unit fixation and noise levels.

Time Wave Form Signal
In theory, all time single start as a pure sinusoid wave. An FFT on this signal
yields a single spectral line. This signal can be distorted be adding harmonic
content, noise mixing with other signals/frequencies. An FFT on such signals
yields the fundamental frequencies, harmonics and noise, and mixed
frequencies.

The transducer converts the mechanical motion into a composite time signal that
contains all frequencies, harmonics, pulses and noise, phase relationships,
amplitude of each cycle, modulation, etc. An FFT on these signals yields spectral
lines at the frequencies and the noise. The amplitude is averaged for the frame
size and the number of frames. The phase relationship of the frequencies is used
during the FFT , but it is not presented in the frequency spectrum. The
modulation type is difficult to determine from the frequency spectrum.

In summary, the time signal contains more information than frequency spectra.
Rotating machines can sometimes generate two or more frequencies that mix
together. Probably the most common case is that of a beat .
Use of Vibration Frequency

From frequency analysis we can detect a source of abnormal vibration amplitude

change ( listed table includes problems related to running frequencies).

Q . What Is Vibration Frequency ?

A . Vibration frequency is expressed in Cycle Per Minute .
Vibration frequency = 1/The time needed for one complete cycle

Use of Vibration Amplitude

Amplitude change levels detect severity of vibration . We have to consider
however what the frequency of this amplitude change .
Vibration Amplitude Units / Tools

 Displacement
The unit is normally thousandths of one inch (mils). It is measured with a
displacement transducer, which actually measures relative motion. There are
two types of displacement transducers: contacting and non – contacting.

 Velocity
The unit is normally tenths of an inch per second. Most measurements are
less than one inch per second .

• Acceleration
This is the rate of change per time . The units of measurement are G’s. Low
frequencies normally have low G’s levels, or a fraction of one-G. Higher
frequencies normally have levels of several G’s. Therefore, at least three
different accelerometers are required. The are low frequency ( 500 m V/g ),
medium frequency ( 100 mV/g ), and high frequency ( 10 or 25 mV/g )
• Flow Pulsation
This is a measure of pressure fluctuations. The selection of pressure
transducers is based on static pressure, amplitude of the fluctuations, and
the frequency of the fluctuations.

 Sound Levels
This is a measure of audible signals, in the range from 20 Hz to 20 kHz .

Microphones are used, but they are not sensitive . They pick up all audible
signals . However, the fact remains that the only way to pick up an audible
signal is with a microphone.
Q . What are the benefits of using phase measurements ?

A . In balancing , the phase measurements help to detect angle to added weight.

It helps in operating deflection shape and mode of operations

Q . How Do We Measure Phase Angle ?

A . Two signals are required to measure the Phase Angle

Rotating shaft vibration pulse is sensed by vibration transducer.

Reference mark in rotating shafts is sensed by photocell, or another vibration
transducer .
Phase Angle = ( Time between two consecutive signals /One revolution time) x ( 360 )
Vibration Transducers

To measure vibration, we should have suitable transducer and instrument

Transducers convert vibration variation forces to electrical signals .

Instruments process & filter this electric signal to a spectrum .

Non –contact transducer is a displacement transducer, but instead of

measuring the displacement of the bearing or housing, it measures the
shaft displacement relative to the bearing and housing .
Q. When do we use non – contact ( proximity probe )

A. Much high speeds or high operating pressures where rotors are mounted in
massive casing and rigid bearings. The weight and stiffness of the massive
machine case and bearings, externally mounted transducer often show little
outward evidence of rotor or shaft vibration . The rotor however might be
vibration excessively within the clearances of the bearing. In such instances,
it is necessary to the actual shaft vibration in order to know when seal and
bearing clearances are in danger . This is the function of the non –contact
transducer .

Q . What is the theory of non-contact ( proximity probe )

operation ?
A . non-contact sensor requires external electronic circuit to generate a very
high frequency AC signal. The vibration of the shaft converts into variation in
the AC signal.
The electronic circuit, called a signal sensor, generates a very high-frequency
electrical signal called the carrier signal . This signal is applied through coaxial
cable, to a small coil of wire in the tip of the non-contact pickup . The high-
frequency electrical signal applied to the coil generates a magnetic filed . Any
metallic object near the coil , namely the steel shaft, absorbs some of this
magnetic energy . This absorption effect places an electrical “ load “ on the
electrical signal, thereby reducing its strength . The amount of loading reding
reduction in strength is inversely proportional to the distance between the coil
and the shaft . The closer the coil to shaft , the greater the loading effect and the
smaller the amount of carrier of carrier signal.

As the shaft moves relative to the tip of pickup , the strength of the electrical
signal changes proportionally to the movement . The signal sensor provides an
AC signal voltage proportional to the amount of vibration . This ( displacement “
signal is sent through a cable to a vibration meter or monitor .
Q. What is the advantage of using non-contact ( proximity probe )
A. Measured actual vibration between rotor and bearings ( not including casing
mobility )

• Can monitored vibration and estimated setting for alarm and shutdown
levels

Q . What are the disadvantages of using no-contact probe ?

A . High initial cost

 Need special fixation ( prefer done through vendor )

Accelerometers
Acceleration is a self-generating device with a voltage or charge output proportional to
vibration acceleration.
Accelerometers measure the rate of change of velocity, normally expressed in
terms of “ G’s “. The “ G “ is the unit of acceleration produced by the force of
gravity, at the surface of the earth. The exact value of one “ G “ will vary with the
latitude and elevation of the point of observation, however , by international
agreement the value of 980 cm/sec sq. = 386 in/sec sq . = 32 ft/sec sq.

Therefore , accelerometers are extremely sensitive to vibration occurring at high

frequencies .

Transducer Selection
There is no such thing as a perfect transducer for all applications . However , one
transducer is best suited for each kind of application . Your task is to select the
transducer best suited for your specific application.

Each type of machine requiring analysis will have characteristics that are unique to
that machine .
For example :

A gearbox or rolling element bearings will produce vibration at high

frequency vibrations that would not be found in a low speed motor.
Large pump or compressor with sleeve bearings where we may want to
observe the shaft displacement as the operating temperature is increased
to determine the effects of temperature change, on the alignment condition
of the rotor in the machine. It is obvious from the two examples that
different parameters must be measured and different transducers are
required to obtain the necessary information. Transducer selection
depends on :
Vibration Parameters
Displacement :

Displacement can be measured with both velocities and acceleration pickup.

This is accomplished by means of integrator circuits that are normally included
in the circuit for your vibration meters and analyzers . Non –contact pickups
respon directly to vibration displacement and are readily available .

Velocity :

Transducers can be used in conjunction with a single integrator to measure

displacement . If you are working with lower frequencies, you must take into
account the fact that seismic velocity transducers attenuate the amplitude below
– 600 CPM. Also the integration process ( mathematically converting velocity to
displacement ) introduces some electronic noise at these lower frequencies
where lower-frequency measurements are important . You can consider a
piezoelectric vibration transducer . These pickups, used with single integration,
can show good displacement measurements down to 1 Hz or 60 CPM.
Accelerometer :

Can be used with a double-integration circuit to measure displacement . As

with a seismic velocity pickup , using an accelerometer pickup to measure
displacement introduces attenation and noise at the lower frequencies . In
this instance , it is very difficult to obtain reliable data below 300 CPM .

The frequency range of vibrations generated in a machine will influence

your choice of pickup . In general , frequency guidelines are :
Q . When We Use Displacement Transducers ?

A . Low frequency range .

For relative measurements
Heavy machines with light weight rotors .

Q. When We Use Velocity Transducers or Velocity Parameters ?

A. Frequency range is 600-100,000 CPM

Transducer will be hand held .
Measuring overall machinery vibration levels .

Q . When We Use the Accelerometer Transducer or Parameter ?

A . Frequency range is 600-600,000 CPM

Measuring structural responses at high frequencies.