Understanding Vibrations

and
Its Role in PdM Program

04/28/23
 Introduction
 Pdm Program and How the Understanding
of Vibration in Rotating Machinery Helps
in Predicting the Health of a Rotating
Machine.
 Understanding Vibrations in Rotating
Machinery and How Its Detection and
Analysis Helps in Identifying Machinery
Problems.
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 Summary of Course
 This Training Is Intended to Help
You to Understand
 Pdm Program.
 What Is Vibration
 Causes of Vibrations.
 Detection, Collection and Analysis
of Vibration Signals.
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 Agenda
 Understanding Predictive Maintenance
Program.
 What is vibration.
 Causes of vibration.
 Characteristics of vibration.
 Vibration severity.
 Detection and analysis of vibration signals
to understand machinery problems.
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 Overview
 Predictive Maintenance Program is an tool
which can be effectively used in determining
the health of and machine. It helps in
planning the jobs in an effective manner.
Vibration measurement data collection and
analysis of this data tells the health of the
machine and is One of the many tools which
is used in preventing costly sudden failures.
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 CONCEPTS OF PdM
PRACTICES & ROLE OF
VIBRATION MONITORING

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 Maintenance Programs
 Different maintenance methods used are

 Breakdown Maintenance
 Preventive Maintenance
 Predictive Maintenance

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 Breakdown Maintenance
 In Breakdown Maintenance, a Machine
is allowed to run until complete failure.
DISADVANTAGES
 Failures can be untimely.
 May require extensive repair.
 Can be catastrophic requiring total
replacement.
 Can lead to a safety hazard.
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 Preventive Maintenance
 In preventive maintenance a machine is
stopped at determined intervals for
inspection and replacement of worn parts
if any. ( e.g. Checklist )

ADVANTAGES
 Lessens the chances of an breakdown.
 Job can be planned.

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 Preventive Maintenance
DISADVANTAGES
 Can be time consuming and expensive.
 Interval between periodic inspection is
difficult to predict.
 A machine which is operating satisfactorily
may be degraded by frequent disassembly.

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 Predictive Maintenance
 The use of graphic trends of selected
measurement parameters against known
engineering limits for the purpose of

DETECTING, ANALYSING & CORRECTING

MACHINERY DEFECTS
BEFORE FAILURE OCCURS

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 Measurement Parameters
 NOISE
 TEMPERATURE
 PRESSURE
 CURRENT FLOW
 INFRA RED THERMOGRAPHY
 OIL ANALYSIS
 VIBRATION

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 4 STAGES OF AN
EFFECTIVE PdM PROGRAM

DETECTION
ANALYSIS
CORRECTION
VERIFICATION

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 INTRODUCTION
TO VIBRATION

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 What Is Vibration

 VIBRATION
IS SIMPLY THE
MOTION OF A MACHINE OR
MACHINE PARTS BACK AND
FORTH FROM ITS POSITION OF
REST.

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 WHAT IS VIBRATION

UPPER LIMIT

NEUTRAL LIMIT

LOWER LIMIT
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 UPPER LIMIT

NEUTRAL POSITION

LOWER LIMIT

UPPER LIMIT
NEUTRAL POSITION
LOWER LIMIT

UPPER LIMIT
NEUTRAL POSITION

LOWER LIMIT
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 UPPER LIMIT

NEUTRAL POSITION

LOWER LIMIT

UPPER LIMIT
NEUTRAL POSITION
LOWER LIMIT

UPPER LIMIT
NEUTRAL POSITION

LOWER LIMIT
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 Why Measure Vibrations
 All machines vibrate.
 Developing problems are usually accompanied
by an increase in vibration.
 The vibrations unique characteristics will be
determined by the nature of the developing
fault.
 Measuring vibration will allow a machine’s
condition to be assessed.
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 Why Measure Vibrations

Vibration x 2 = Bearing Life

8
Vibration x 4 = Bearing Life
64
CURE HIGH VIBRATION PROBLEMS

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 Why Measure Vibrations
 Load is Dynamic
 Increased dynamic forces reduce life of
bearings drastically.
 Amplitude of machinery vibration is directly
proportional to the amount of dynamic forces
generated.
 If generated force is lowered, the vibration is
lowered and machine life is increased.
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Forces That Cause Vibration
 Forces that change in direction with time
 Rotating unbalance
 Misalignment
 Forces that change in amplitude with time
 Motor problems
 Bearing problems

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Forces That Cause Vibration
Misalignment.
Unbalance.
Bent shaft.
Bearing defects.
Gear defects.
Aerodynamic forces.
Hydraulic forces.
Reciprocating forces.
Rubbing.
Electrical defects.
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 Forces That Cause Vibration
 Some problems amplify any vibration that is
present
 Looseness
 Resonance

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 CHARECTERISTICS OF VIBRATION

MIN. VELOCITY

MAX. ACC D
I
MAX. S
VELOCITY P
L
A
C
E
M
E
MAX. ACC N
T
FREQUENCY
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 CHARECTERISTICS OF VIBRATION

P P
k
e
a AVG
T
k o
RMS
P
k

RMS = Pk / 1.414
AVG = Pk / 1.571
Pk To Pk = 2 x Pk
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 Characteristics Of Vibration

Characteristics that identify a vibration

AMPLITUDE HOW MUCH

FREQUENCY How often ? IDENTIFIES

POSSIBLE DEFECTS

PHASE PINPOINTS PROBLEMS

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 CHARECTERISTICS OF VIBRATION

P
E P D
A E I
K S
A P
T K L
O A
C
P E
E M
A E
K N
T

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Characteristics of Vibrations
 DISPLACEMENT

Displacement is a measure of the total

travel of the mass - back and forth.

Unit of measurement = Microns

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 Characteristics of
Vibrations
 DISPLACEMENT
The total distance traveled by the vibrating
part from one extreme limit of travel to the
other extreme limit is referred to as “ Peak -
Peak” displacement. It is normally
expressed in microns where 1 micron
equals 1 thousandth of a millimeter (0.001
mm)
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Characteristics of Vibrations
 DISPLACEMENT

Displacement is most useful parameter in

frequency ranges less than approx.. 600 CPM.
Displacement is more effective when
measuring the shaft movement using an non
contact type pick up

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 CHARECTERISTICS OF VIBRATION
MIN. VELOCITY

MAX.
VELOCITY

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Characteristics of Vibrations
 VELOCITY

Velocity of the Vibration is a measure of

speed at which the mass is moving or
vibrating during its oscillation.

Unit of Measurement = mm/sec

In/sec
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 Characteristics of
Vibrations
 VELOCITY
Since the vibrating weight is moving, it must be
moving at some speed. However the speed is
constantly changing. At the top limit the speed is
Zero since the wt must come to a halt before it
can go in the opp direction. The speed of velocity
is greatest as the wt passes thro the neutral
position. Velocity is measured in mm/sec peak

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Characteristics of Vibrations
 VELOCITY
Velocity is more effective when the
Vibration frequency range is from 600
CPM to 60 k CPM.

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 CHARECTERISTICS OF VIBRATION

MAX. ACC

MIN. ACC

MAX. ACC
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Characteristics of Vibrations
 ACCELERATION

Acceleration is the rate of change of

speed of the mass during its oscillation.

Units of Measurement = g’s

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Characteristics of Vibrations
 ACCELERATION
Acceleration is recommended to be used
when vibration sources within the
machine generates frequencies over
approx. 120 k CPM.

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 Vibration Severity Chart ( ISO 2372 )
Range of Vibration Eg. Quality judgement for separate
Severity In Velocity class of machines
Units Of Range Small Medium Large Turbo
mm/sec Machines Machines Machines Machines
Peak RMS Class 1 Class II Class III Class IV
0.40 0.28
0.64 0.45 A
1.0 0.71
A
A
1.58 1.12 B A
2.50 1.80 B
4.00 2.80 C B
6.40 4.50 C B
10.0 7.10 C
15.8 11.2 D C
25.0 18.0 D
40.0 28.0 D D
64.0 45.0
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A-GOOD B-USEABLE C-STILL ACCEPTABLE D-UNACCEPTABLE
MACHINE CLASSIFICATION IN ACCORDANCE WITH ISO 2372

•Class I - Individual parts of engines and machines

integrally connected with the complete machine in its
normal operating condition. ( Production electrical
motors of up to 15 Kw are typical examples of
machines in this category.

•Class II - Medium size machines , ( typically

electrical motors with 15 to 75 Kw output ) with
special foundations, rigidity mounted engines or
machines ( up to 300 Kw ) on special foundations.
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 MACHINE CLASSIFICATION IN ACCORDANCE WITH ISO 2372

•Class III - Large prime movers and other large

machines with rotating masses mounted on rigid and
heavy foundations which are relatively stiff in the
direction of vibration measurement.

•Class IV - Large prime movers and other large

machines with rotating masses mounted on
foundations which are relatively soft in the direction
of the vibration measurement ( for e.g. turbo
generator sets, especially those with light weight sub
structures).
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 SPIKE ENERGY
When defects occur on bearing raceways or
elements they produce bursts of energy
when the defects come in contact with other
elements. This energy occurs in high
frequencies and they are measured in terms
of Spike Energy.

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 DATA ACQUSITION

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 Data Acquisition

 The most important and critical function

for successful analysis is the accurate
collection of data.

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 Data Acquisition
 The following steps are to be followed
before carrying out Vibration Analysis
 Identify the Machine
 Know its RPM
 Know its Bearings ( Helps in identifying
bearing defect frequencies )
 Know the No. of Vanes / Blades ( Vane
passing / Blade passing frequencies )
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 Data Acquisition
 The following steps are to be followed
while carrying out Vibration Analysis
 Identify the points on the machine where
the data is to be collected,
 Collect readings at the same location
everytime.
 Select the correct parameter.

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VIBRATION MEASUREMENT POINTS
ON AN OVERHUNG PUMP

4V 3V 2V 1V
4A
3A 2A 1A

1H
4H 3H 2H

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 VIBRATION MEASUREMENT POINTS
ON AN CENTER SUPPORTED PUMP

4V 3V
2V 1V

3A 2A 1A
4A

1H
3H 2H
4H

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 VIBRATION
ANALYSIS

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 Fundamentals of Vibration
Analysis
 Define the problem
 Create base,line for future analysis
 Identify the cause for excessive Vibration
 Identify the cause of significant vibration
increase
 Identify the cause of frequent component
failures like Brg, Coupling, Seals, Shaft.
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Steps for carrying out Analysis
 Determine machine history.
 When did the problem exactly start.
 Determine the machine details.
 Visual Inspection.
 Probing studies.

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 FFT SPECTRUM ANALYSIS

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 TIME WAVEFORM

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 PHASE DATA

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 Problems Causing High Vibrations
 Unbalance
 Looseness
 Defective Bearings
 Electric Problems
 Hydraulic Forces
 Misalignment
 Eccentricity
 Defective Gear
 Resonance
 Aerodynamic Forces
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Vibration Frequencies & Likely Causes
FREQ CAUSES
1 X RPM UNBALANCE
2 X RPM Mechanical
Looseness
3 X RPM Misalignment
Less than 1 Oil Whirl ( less
x RPM than ½ X RPM)
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OTHERS
Eccentric Journals, Gears,
Pulleys. Misalignment, Bent
Shaft, Resonance, Electrical
Misalignment if high axial
Resonance,
Combination of misalignment &
excessive clearances.
Background Vibration, Beat
Vibration
Vibration Frequencies & Likely Causes
FREQ CAUSES OTHERS

Synchronous Electrical Includes broken rotor bar,

(AC line eccentric rotor, unequal air gap.
frequency)
Many times Bad Gears, Gear teeth times RPM.
RPM Aerodynamic No of Fan blades times RPM
(Harmonically forces,
related) Hydraulic, No of impeller vanes times
Looseness RPM
2,3,4 & higher if severe
looseness
High Bad anti Cavitation, Rubbing, Improper
Frequency( friction lubrication of journal brgs.
Not bearings
harmonically
related)
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 98 P 829 B ( MISALIGNMENT)

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 98 P 829 B ( MISALIGNMENT)

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 98 P 829 B ( MISALIGNMENT)

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 98 P 829 B ( MISALIGNMENT)

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