CHAPTER 3 : VIBRATION MEASUREMENT –

SELECTING AND USING PICKUPS

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VIBRATION MEASUREMENT is for determining the radial
motion of the rotor shaft. The output signal gives all the information
about the problem of the rotating machine such as misalignment,
cracked shaft, oil whirl, unbalance, or any other dynamic snags.

Vibrating Vibration Signal

machine or transducer conversion Display unit Data analysis
structure or pickup unit

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MISALIGNMENT UNBALANCE

OIL WHIRL CROOKED BEARING

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REASONS FOR THE MEASUREMENT OF VIBRATION

1. Some machines are running at high speeds which may

cause resonant condition and they may get fail.

2. In some situations the excessive vibrations may

transfer to the nearby machines or structures.

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REASONS FOR THE MEASUREMENT OF VIBRATION

3. To check the health of the machines.

4. To understand the dynamic behavior, it is

necessary to measure the vibrations.

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REASONS FOR THE MEASUREMENT OF VIBRATION

5. It helps to identify important

parameters of the system such as mass,
stiffness, and damping.

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 CLASSIFICATION OF VIBRATION
MEASURING INSTRUMENTS

BASE ON DISPLAY TIME BASE BASE ON POWER

BASE ON CONTACT
METHOD MEASUREMENT SOURCE

CONTACT INDICATING REAL TIME ACTIVE

TYPE TYPE BASED SYSTEM

NON-
RECORDING NON-REAL PASSIVE
CONTACT
TYPE TIME BASED SYSTEM
TYPE
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CONTACT TYPE

Handheld Vibration Meter

(Source: https://sea.omega.com)

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NON-CONTACT TYPE

MSL-7000 Laser Vibrometer

(Source: https://www.skf.com)

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INDICATING TYPE

Fluke 805 Vibration Meter

(Source: https://www.fluke.com)

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RECORDING TYPE

LUTRON BVB-8207SD
(Source: https://sib7.com)

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REAL TIME BASED

HUATEC Portable Real-time

Vibration Meter For Industrial
Fields HG-6380
(Source: https://www.alibaba.com)

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NON-REAL TIME BASED

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ACTIVE SYTEM TYPE

FFT Analyzer
SR770 — 100 kHz FFT analyzer
(Source: https://www.thinksrs.com)

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PASSIVE SYSTEM

Frahm tachometer
(Source: https://maas.museum)

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VIBRATION PICKUP
The electronic instruments used for measuring machinery vibration are
generally classified as meters, monitors and analyzers. Monitors serve much the
same purpose as meters, but are permanently or semi-permanently installed to
provide continuous monitoring of machinery vibration.

All IRD vibration meters, monitors and analyzers use a vibration transducer
which is often referred to as a vibration pickup or sensor. A transducer is a
sensing device which converts mechanical vibration into an electrical signal.

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VELOCITY PICKUPS
Velocity pickups or transducers, respond directly to vibration velocity.
They are used for measuring vibration displacement and velocity.

Electrodynamic velocity pickup

(Source: https://www.imv.co.jp)

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SEISMIC VELOCITY PICKUP (Moving Coil Type)

Seismic velocity transducers

(Source: http://www.power-mi.com) 19
 Theory of Operation

Whenever this transducer is fixed or held tightly against a vibrating

object, the permanent magnet vibrates, while the spring-suspended coil of
wire remains stationary in space. When a coil of wire cuts magnet lines of
force, a voltage is generated in that wire. The voltage is proportional to the
velocity of motion, the strength of the magnetic field, and number of turns
of wire in the coil. The voltage generated is transmitted by cable to a
vibration meter, monitor or analyzer.
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 Characteristics
 Rugged  Self-generating
 Easy to apply  Require no power input
 Hand held  Large
 Have relatively high electrical  Weigh more than other pickups
output levels

The voltage generated in a seismic velocity transducer is normally expressed

in terms of millivolts per inch per second which is the sensitivity specification for
the pickup.
At low frequencies of vibration, the sensitivity decreases because the coil no
longer remains fixed in space, but tends to follow the motion of the magnet. 21
 If you are taking readings with an analyzer and must have accurate,
filtered, amplitude readings in the low frequency range, you can use a
correction factor chart. To use the chart, simply:
 Note the frequency of the vibration on the scale along the bottom of
the graph
 From this point, move straight upward to the curve
 Then cross over to the vertical axis and read the value of the correction
factor from the scale
 Multiply the observed amplitude reading times the correction factor.
The result is the true amplitude of vibration 22
Magnetic Interference
The seismic velocity transducer uses a fixed, internal magnetic field as part of its normal
operation. Any distortion of this magnetic field is bound to interfere with the accuracy of
the measurements.
 Connect the pickup to the analyzer just as you would for measuring the machines
vibration
 Suspend the vibration pickup by its cable in the area where vibration readings are
normally read
 Hold the cable steady and do not allow the pick up to touch the machine
 Tune your analyzer to the AC frequency of the machine and note the amplitude reading.
This is the signal caused by AC magnetic interference. 23
 If you find a significant amount of AC interference, it is recommended
that you install the pickup within a magnetic shield. A magnetic shield can
reduce magnetic interference by a ratio of 100 to 1..

A temporary solution to magnetic interference is to use a long extension

probe. The long probe simply locates the pickup away from the magnetic
field, thereby reducing the interference level. This is recommended only as a
temporary procedure because the use of a longer probe limits the upper
frequency response
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DIRECT-PROD VELOCITY PICKUP (Moving Coil Type)

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Theory of Operation
The principle of operation of a direct-prod pickup is identical to that of a
seismic velocity pickup. With the direct-prod pickup, however, a thin prod
extends through the endcap of the pickup and is attached directly to the
moveable coil inside.

To measure vibration with a direct-prod pickup, you should fasten the

main body of the unit to a rigid structure (one with no significant vibration)
to serve as a point of reference. The tip of the prod is then attached to the
vibrating part, using a threaded tip or a special magnetic tip.
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Characteristics

Since the pickup coil is moved directly by the prod, while the pickup case
remains stationary, the sensitivity of this type of pickup does not drop off at
low frequencies. It is suitable for measurements down to very low
frequencies (e.g. 50 CPM) which makes it valuable for balancing machine
applications.

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Magnetic Interference

The direct-prod velocity pickup is subject to the same magnetic

interference problems, and corrective measures, as the seismic velocity
pickup.

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SEISMIC (PIEZOELECTRIC) VELOCITY PICKUP

Piezoelectric transducers
(Source: http://www.power-mi.com) 29
Theory of Operation

A seismic velocity pickup serves all the purposes but uses a different
principle of operation. These units have an output that is proportional to
velocity, but have no internal moving parts. Stresses due to vibrational
forces applied to the pickup cause a crystal or special ceramic material to
produce an electric charge.

The electrical charge from the piezoelectric element is so small that the
signal must be amplified before it can be measured.
30
Characteristics

The built-in amplifier provides a high output signal and low impedance
to enable it to drive long cables without signal loss. The low residual noise
combined with small phase shift makes it an ideal transducer for low
speed balancing applications.

Magnetic Interference

Under most conditions the piezoelectric velocity pickup is not affected by

magnetic fields.
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ACCELEROMETERS
An accelerometer is a self-generating
device with a voltage or charge output
proportional to vibration acceleration.
Acceleration is a function of
displacement and frequency squared. As
a result, accelerometers are extremely
sensitive to vibration occurring at high
frequencies.
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SEISMIC (PIEZOELECTRIC WITH BUILT-IN AMPLIFIER)

Acceleration transducers, or accelerometers, produce a voltage that is proportional to

the acceleration characteristics of vibration. This makes the accelerometer particularly
useful for measuring and analyzing the vibration from gears and rolling-element bearings.
Accelerometers are often permanently installed to continually monitor the vibration of gas
turbines and other machines operating at very high rotating speeds.

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SEISMIC (PIEZOELECTRIC WITH BUILT-IN AMPLIFIER)

(Source: Measuring Vibration with

Accelerometers, http://www.ni.com)
34
Theory of Operation

When this pickup is fixed or held against a piece of vibrating machinery, the mechanical
vibrations are passed through the frame to a piezoelectric material. This material has the
ability to generate an electric charge in response to a mechanical force applied to it. In this
instance, mechanical vibration produces the force and the piezoelectric material responds
by generating an electrical charge that is proportional to the amount of vibration
acceleration.

The fact that an accelerometer responds directly to the acceleration characteristics of

vibration accounts for its name.
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Characteristics
Accelerometers are small, lightweight, rugged transducers that operate
over wide frequency and temperature ranges and withstand high vibration
levels. They are an important type of vibration sensor and find wide
application in vibration monitoring systems as well as vibration analysis
applications.
In addition to its sensitivity to high frequency vibration, its small size and
light weight make the accelerometer especially well-suited for applications
where space is limited or where pickup mass is important.
36
Magnetic Interference

Accelerometers are not affected by external magnetic fields but are

more susceptible to ground loops, radio frequency interference, and
dirty or poor contacts. Cable length effects may reduce sensitivity.

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NON- CONTACT (PROXIMITY) TRANSDUCERS

It is necessary to measure the actual shaft vibration in order to know when

seal and bearing clearances are in danger. It is basically 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.

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 Digital transducer for noncontact
linear position and displacement
sensing
(Source: https://www.controleng.com)

39
Theory of Operation

Non-contact transducers can be used with portable meters and analyzers

as well as permanently mounted monitors. Unlike velocity and acceleration
transducers, however non-contact transducer does not have an element that
generates a voltage or electrical charge in response to vibration. Non-contact
sensor requires external electronic circuitry to generate a very high-frequency
AC signal and detect vibration in the AC signal caused by the vibration of the
shaft.
40
Installation

Non-contact pickups can be supplied in many configurations. Some are

only 3/4 inches long, while others are several inches long. Where some
pickups have a threaded body for installation in tapped holes, others have a
smooth body for permanent installation with set screws or epoxy cement.

Some non-contact pickups have an integral waterproof, oil tight connector;

and some have Teflon cables. To provide maximum protection from cable
damage, some cables have armored covers.
41
Installation

For field installations where there are no provisions for mounting the
pickups in the bearing, the pickup can be mounted in a rigid bracket or
adapter. Keep these adapters as short as possible, yet massive, in order to
reduce vibration of the mounting. Make sure these adapters are securely
fastened to the machine.

42
MOUNTING OF TRANSDUCERS

1. Stud mounting

2. Epoxy Mounting

3. Hand-held without Probe

4. Hand-held with a standard 9-inch Probe

5. Magnetic holder

6. Vise-grip Pliers

7. Shaft Stick 43
Stud Mounting
A very reliable mounting technique is to attach the
transducer to the measurement surface with a threaded
stud. The entire face of the transducer should be flat
against the mounting surface. Avoid incorrect mounting
conditions. It is possible to attach mounting studs either
by welding or gluing a suitable sized mounting pad and
stud to the bearing cap in some instances.

44
Epoxy Mounting
Often it is impractical to drift a
hole in the mounting surface. This is
where cementing or epoxy mounting
techniques are useful. Many types
are available. Low temperature cure
epoxies or special cements may be
used. Special care must be used to
make sure that the face of the pickup
is attached rigidly and in direct
contact with the mating surface so no
decoupling takes place.
45
Hand-held without Probe
A hand-held transducer, without a probe, is quite satisfactory for periodic
vibration checks and analysis applications. The transducer should be held
against a reasonably flat surface. When applying the transducer to curved or
irregular surfaces, bear in mind that the transducer measures a vibration only
in the direction parallel to the transducer axis, and any unsteadiness of the
hand which allows the direction of the axis to vary can result in unsteady
vibration readings.
Use only enough pressure to keep the transducer from chattering or
walking on the surface. A tingling sensation in the hand indicates the
presence of high frequency vibration, and you should apply more pressure in
order to get a reliable reading.
46
Hand-held with a standard 9-inch Probe
The standard 9-inch probe supplied with IRD
Mechanalysis meters and analyzers is a convenient
device for reaching-out-of-the-way points and for
locating the transducer at a very specific point on the
machine. This probe can be used for periodic checks and
analysis applications, but care must be exercised since its
use significantly reduces the frequency range of the
transducer with which it is used.

47
Magnetic holder
The magnetic holder provides a quick
and convenient method for mounting
pickups. The holder should be mounted on a
reasonably flat, smooth and clean surface. If
the magnetic surface is not flush with the
mounting surface, the holder can rock at
some unpredictably low frequency, thereby
producing erroneous readings. Dirt or grease
between the magnet and mounting surface
reduces the holding power of the magnet
and the maximum usable pickup frequency.
48
Vise-grip Pliers
Transducers can be mounted to a machine with the aid of vise-grip pliers.
The jaws should be in contact with the mounting surface along their entire
length.
The vise-grip mounting technique is actually a convenience for use during
in-place balancing. It is not recommended for vibration analysis because of
the limited frequency range.

49
Shaft Stick
A shaft stick is simply a hardwood, fish-tailed
shaped stick that is outfitted with a stud for
attaching a transducer. The fish-tail shape provides
two points of contact required for keeping the stick
on the circumference of a rotating shaft and it also
permits the stick to ride on shafts of almost any
diameter. The fish-tail end is also tapered to provide
a smaller contact area, thereby reducing friction
and chatter.

50
The Shaft Rider Accessory
A shaft stick is usable for periodic
vibration checks and some analysis
and in-place balancing operations.
However, when it is necessary to
monitor shaft vibration for extended
periods of time, it is recommended
that you use a shaft rider accessory.

51
The Shaft Rider Accessory
A shaft rider is permanently installed in the bearing housing. It consists of
a spring-loaded probe that is held firmly against the rotating shaft so that it
accurately follows shaft motion.
The probe is fitted with a long-wearing, non-metallic tip which is installed
within the bearing area to provide tip lubrication. A seismic velocity pickup or
accelerometer mounted to the shaft rider provides an electrical output that is
proportional to the absolute shaft vibration.
Shaft rider transducers are normally installed on large rotating machines
such as turbo-generators with massive rotors. On these and similar machines
where shaft speeds are moderate, a measure of absolute shaft vibration is
preferred for monitoring and in-place balancing operations.
52
Guidelines for Transducer Selection
• Selecting transducers
• Mechanical characteristics of the machine
• Considering measurement parameters
• Measurement parameters
• Frequency range

53
Selecting Transducers
There is no such thing as a perfect transducer for all applications.
However, there is one transducer that is best suited for each kind of
application. Your task is to select the transducer best suited for your specific
application. It is a very important step to obtain an accurate and reliable
vibration data.
Transducer selection depends on: Mechanical characteristics of the
machine; Parameters to be measured; Frequency range of the vibrations; and
Mounting considerations.

54
Mechanical Characteristics of The Machine

Bearing Clearances of a Machine Rotor position and shaft vibration

55
Mechanical Characteristics of The Machine

Relative to the Bearing Housing Shaft vibration relative to space

56
Considering Measurement Parameters

Displacement, Velocity, and Acceleration are the parameters to be

considered in measuring vibrations.
57
Measurement Parameters

It is best to choose a pickup that will measure the parameter directly:

displacement pickups for measuring displacement, velocity pickup for
velocity readings, and accelerometer for acceleration measurements. By
integration, it is possible to convert velocity readings to displacement and
acceleration to velocity or displacement with excellent results.

58
Frequency Range
The frequency range of vibrations generated in a machine will influence
your choice of pickup. In general, frequency guidelines are:

a) Use displacement transducer for:

1.Low frequency, below approximately 600 CPM (cycles per minute)

2.For relative measurements
3.Heavy machines with light weight rotors
4.Rotor position

59
Frequency Range
b) Use velocity transducers or velocity parameters when:

1.Frequency range is 600-100,000 CPM

2.Transducers will be handheld
3.Measuring overall machinery vibration levels
4.General analysis procedures
5.Cable lengths to 1000

60
Frequency Range
c) Use the accelerometer transducer or parameter for:

1.Frequency range is 600-600,000 CPM

2.Measuring structural responses at high frequencies
3.Spike energy measurements on rolling element bearings, gears and
gear drives, and high frequency aerodynamic vibration sources (blade
passing frequencies).

61
Selecting a Particular Pickup
The selection is usually made on the basis of requirements such as
temperature range, humidity, electrical characteristics and environmental
factors.

62
 Parameter Transducer Selection Chart

Machine Description Parameter Frequency Range in CPM Location Transducer

Steam turbine/large pump Disp. 600-6,000 Relative shaft Non-contact or shaft rider
compressor with Velocity or
fluid film bearings Velocity 600-60,000 Bearing mounted Accelerometer

Pumps-motor or turbine Velocity 600-60,000 Bearing mounted Velocity or

driven Accelerometer
Electric Motors/fans Acc. 600-600,000 Bearing Mounted Accelerometer
Spike Energy

Fans & blowers, motor Velocity 600-60,000 Case Velocity or

driven with rolling Spike Energy Accelerometer
element bearings Acc. 600-600,000 Case Accelerometer

Gearbox with rolling Acc. 600-600,000 Case Accelerometer

element bearings Spike Energy

Gearbox with fluid Disp. 600-6,000 Relative shaft Non-contact

film element bearings Acc. Case Accelerometer
Spike Energy 600-60,000

Special cases
Very low frequency

Cooling towers Velocity

Disp. 60-60,000 Case (Piezoelectric)
Hydroelectric
generators low speed fan
63