Lecture 13 Vibration Analysis and Troubleshooting

Lecture 13 Vibration Analysis and Troubleshooting

Lecture Overview
SHM/CM/SPC Comparison

Data-Driven Approach

Model-Driven Approach

Vibration Monitoring for Machine Damage

Data to Decision Sensor Issues Signal Processing Feature Extraction Pattern Processing

Lecture 13 Vibration Analysis and Troubleshooting

Lecture Overview

Vibration Sources

Rotating Machinery Reciprocating/Linear Machinery

Vibration Analysis Techniques and Video Machine Failure Mode Analysis

General Failure Modes

Lecture 13 Vibration Analysis and Troubleshooting

Vibration Sources

All machinery with moving parts generates mechanical forces during normal operation. As mechanical condition of machine changes because of wear, changes in operating environment, load variations etc., so do these forces. Vibration profile that results from motion is the result of a force imbalance there is always some imbalance in real-world applications.

Lecture 13 Vibration Analysis and Troubleshooting

Rotating Machinery Vibration

A rotating machine has one or more machine elements that turn with a shaft e.g. rollingelement bearings, impellers and other rotors. In a perfectly balanced machine, all rotors run on their true centreline and forces are equal. In industrial machinery, rotors imbalance will generally be present due to uneven weight distribution or due to the imbalance between generated lift and gravity.

Lecture 13 Vibration Analysis and Troubleshooting

Rotating Machinery Vibration

Pumps, fans, compressors will be subject to imbalance caused by turbulent or unbalanced media flow. Combination of these forces with stiffness of rotor-support system will determine the vibration level.

Lecture 13 Vibration Analysis and Troubleshooting

Reciprocating/Linear Vibration

Reciprocating linear-motion machines incorporate components that move linearly in a reciprocating fashion to perform work. They are bidirectional in that the linear movement reverses. Non-reciprocating linear machines also generate work in straight line but do not reverse direction. Few machines involve linear reciprocating motion alone e.g. reciprocating compressor contains a rotating crankshaft that transmits power to reciprocating pistons for compression.
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Reciprocating/Linear Vibration

Vibration profiles of reciprocating machines reflect combination of rotating and linear-motion forces. Frequencies are not always associated with one complete revolution of shaft e.g. four-cycle engine requires two crankshaft revolutions to complete a cycle of all pistons. Level of unbalanced forces substantially higher than those generated by rotating machines spikes in vibration profile due to direction reversals. (Linear-motion-only machines do not generate these spikes).
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Vibration Analysis Techniques

Three main techniques used in vibration analysis:

Trending Comparative Analysis Signature Analysis

Most vibration-monitoring programs rely heavily on historical vibration-level amplitude trends as their dominant analysis tool. The measures are derived from the vibration signal and may be mean vibration, peak vibration, peak-to-peak vibration, RMS vibration or kurtosis.
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Vibration Analysis Techniques

Root Mean Square (RMS) Level

xRMS 1 2 = x (t )dt T 0
T

Kurtosis gives an indication of the spikiness of the T data. 4

K=

[ x(t ) x ]
0 4 xRMS

dt

The measures may be taken overall full frequency range (broadband) or narrowband.
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Vibration Analysis Techniques

Comparative analysis directly compares two or more data sets in order to detect changes in operating condition of machine. Limited to direct comparison of time- or frequencydomain signature generated by machine. Comparison may be machine baseline or industry standards. Baseline must be updated after maintenance and correct baseline should be used (i.e. same process variables such as load).
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Vibration Analysis Techniques

Signature analysis provides specific data on every frequency component within overall frequency range of machine-train. Important analysis tool but require large storage space. Although possible to record broadband signatures, it is usually the case that narrowband signatures are recorded in the vicinity of one or more of the running speeds.

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Vibration Analysis

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Machine Failure Mode Analysis

Failure-mode analysis attempts to pinpoint the failure mode and identify which machine-train component is degrading. Does not always identify the true root-cause of the problem visual inspection, NDT may be required to verify root-cause. Two types of information required:

Machine train vibration signatures (FFT and time) Practical knowledge of machine dynamics and failure modes.

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Machine Failure Mode Analysis

Several failure-mode charts available but 60 to 70% of the total vibration energy is contained in the frequency component corresponding to the running speed of the machine. Many common causes of failure in machinery components can be identified by understanding relationship to running speed of shaft. Common machine-train failure modes include critical speeds, imbalance, mechanical looseness, misalignment, modulations and process instability.

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Machine Failure Mode Analysis

Critical speeds result due to the natural vibrating frequencies of the machine-train they are functions of the mass and stiffness of the machine. When the running speed coincides with one of the critical speeds excessive vibration occurs which is generally undesirable. Best way to confirm a critical-speed problem is to change running speed amplitude of vibration components (1x, 2x, 3x running speed) will immediately drop if problem is due to criticalspeed.
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Machine Failure Mode Analysis

Balance means that all forces generated by rotating element of machine-train are in equilibrium. Any change in state of equilibrium creates an imbalance. Imbalance is one of most common condition monitoring problems. All machines exhibit some level of imbalance. Dominant frequency component is at running speed (1x) of shaft. Harmonics (2x,3x, etc.) may be observed in multi-plane imbalance.

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Machine Failure Mode Analysis

Mechanical looseness (e.g. poor bolting to foundations) can be present in vertical and horizontal planes and can create a variety of patterns in vibration signature. In some cases only 1x frequency is excited but generally full and half multiples of the running speed are present in spectra (0.5x, 1x, 1.5x, 2x etc.)

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Machine Failure Mode Analysis

Misalignment is virtually always present in machine-trains. Three types of misalignment: internal, offset and angular. All three types excite 1x frequency as they create an apparent imbalance in machine. Internal and offset also excite 2x frequency as shaft creates two high-spots
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Alignment

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Machine Failure Mode Analysis

Modulations are frequency components that appear in vibration signature but cannot be attributed to any specific physical cause or forcing function. Although they are ghost or artificial frequencies they can result in significant machine-train damage. Ghosts are caused when two or more frequencies combine to produce another frequency component. Not an absolute indication of problem within machine-train but increased amplitude can amplify defects.
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Machine Failure Mode Analysis

Modulation example: Consider 10-tooth pinion gear rotating at 10rpm whilst driving 20-tooth bullgear with output speed of 5rpm. Gear generates frequency components at 5, 10 and 100rpm (i.e. 10 teeth x 10rpm). This set can generate ghost frequencies at 15rpm (10+5), 110rpm (100+10), 95rpm (100-5) etc.

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Machine Failure Mode Analysis

Process instability is normally associated with bladed or vaned machinery such as fans and pumps. Process instability creates an unbalanced condition within the machine which generally excites the fundamental (1x) frequency and the blade-pass/vane-pass frequency components.

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Machine Failure Mode Analysis

Typical vibration troubleshooting chart:

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Next Lecture

Bearing Failure Modes Gear Failure Modes Non-Destructive Testing Methods

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