Vibration TroubleShooting Guide

Reprinted from Reliabilityweb.com at http://www.reliabilityweb.
com
Vibration Trouble-shooting Field Guide
by Sam Pickens of PDM Engineering
What is vibration? There are three basic types; Linear, Bending and Torsion. Three basic types
of transducers for machinery vibration study; acceleration, velocity and displacement. Three basic
parameters; acceleration, velocity and displacement. So we need to be able to observe these
phenomena in an easily understood way via data acquisition instrumentation. We can then apply
200-year-old math to decipher the meaning of the data represented on the instrument.
Shown is a typical modern day vibration acquisition system. There are several good ones on the
market.

It has certainly changed since I bought one of the first ADRE systems in 1981. That was back in
the days of HP-9000 (300) used as controllers for real time analyzers.
Fast Fourier Transform (FFT) is modern technology applying Jean Baptiste Fouriers (1768-1830
AD) formula into electronic format displaying time wave form data into frequency spectra.
This really makes time wave form data from machinery vibrations meaningful and somewhat easy
to interpret.
Disclaimer (to make the lawyers happy): This information is supplied by third parties and is not warranted for any
purpose. The reader is responsible for ensuring accuracy and compliance with all policies, regulations and laws.
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Reprinted from Reliabilityweb.com at http://www.reliabilityweb.com

Mr. Ray Dodd is held in esteem as the guy that fathered the modern day predictive maintenance
(PdM) programs. In the 1970s we were basically carrying a portable instrument and collecting
vibration data via a velocity transducer and recording that data onto a chart with pen in hand. If
overall level vibrations above a certain magnitude were encountered, then we would pick out the
predominate frequencies and log them as well. A long process, but one that proved its worth.
This writing is to serve as a help and guide to assist in diagnostics of vibration problems. First
well make sure that certain terms are defined to avoid confusion.
FUNDAMENTAL: This is running speed or 1X; referred to as the machines fundamental or
fundamental component. Also component fundamental is sometimes used; i.e. the bearings ball
pass frequency fundamental is expressed as component fundamental to distinguish it from
harmonics in a ball pass problem within the spectra. Always make sure it is defined if used for
anything other than running speed.
FIRST HARMONIC: Some confuse this with the symbols 2X and 1X; the first harmonic (primarily
an acoustical term) is also referred to as two times RPM (2X). So, be careful. One should
visualize this as a bell. The bell is the center of concentric circles circles or harmonics are
numbered from the center. The bell is the center and the first circle encountered is the first
harmonic. But in machinery terms, that would be the 2X component. [The bell, itself being the
fundamental or 1X component].
BEARING COMPONENT: BPFI (Ball Pass Frequency Inner Race)
BPFO (outer race frequency)
BSF (Ball Spin Frequency)
FTF (Fundamental Train Frequency) cage problem
Heres the so-called classic bearing equation
w = shaft speed in RPM h = contact angle Pd = Pitch diameter Bd = Ball diameter
BPOR = w
N
/
2
Bd
/
Pd
(1
Bd
/
Pd
cosh) BPIR = w
N
/
2
(1 +
Bd
/
Pd
cosh)
BSF = w
Pd
/
2Bd
(1 (
Bd
/
Pd
)
2

cos
2
h) FTF = w/2(1
Bd
/
Pd
cosh)
2
And then theres the easy way: The rule of thumb method.
BPOR
rot
~ 0.4wn BPIR
rot
~ 0.6wn FTF
rot
~ 0.4w
Theres no substitute for experience; again use acceleration, you cant analyze what you cant
see you cant trend what you cant see or your instrumentation doesnt see. Integration can
often drive signals into the dirt or noise floor where theyll be hidden or camouflaged to death. The
noise floor masks or covers them up, and a small acceleration signal 0.05 gs 0-P (the beginning
of trending) at 600 Hz wouldnt be noticed.
Always check the limitations of your system. Transducer selection for a paper machine should be
of very high resolution with as low a frequency response, as temperature will allow. There are a
number of good transducers out there. Always make sure your acquisition system is within limits
of your interest.
Ive seen so-called consultants gather vibration data when the machine of interest was outside of
the limitations of their instrumentation. Naturally, the sub sequential report that follows is a real
gem. This writing is only a field book and to inform you of certain things that should be of concern
to you in your environment. Question your transducer supplier but make certain they have the
product you need or find one who does.
Bearings Natural Frequency: Lack of lubrication excites this frequency and creates a broad
vibration pattern around this frequency region casing this phenomenon to display in the vibration
spectra.
Special Note: A broadened spike or spectral peak (from the peak on top, the shape of the peak
will broaden toward the noise floor) will denote mechanical deterioration. If you see mechanical
deterioration and the bearings natural frequency you may want to inject grease lubricant very
slowly as not to shock the bearing. If theres only a small magnitude of vibration then you may
want to only note it in the report. If its severe and a determination must be made the addition of
lube may give insight as to time of failure or assist in analysis.
LINE FREQUENCY: 60 Hertz (Hz) USA Power Turbine RPM (3600)/60=60. In Europe the power
is 50 Hertz so the generators are larger and operate at 3000 RPM.
LINE SYNC FREQ: 120 Hz (120 / # poles X 60 = RPM of a given machine) Look for especially in
DC motors. In AC & DC this frequency phenomenon is generally found at upper harmonics of
high frequency problems associated with electrical problems or the beginning of potential
problems.
The electrical frequency is also displayed in fluorescence light bulbs and is used to calibrate a
photo tachometer Ive also used it for a trigger.

Field balancing using a tachometer for a trigger device to sync at once per rev.
Overall or Overall level (OA): A term I use often, but not really sure if all are versed in its
meaning. Normally an analyzer has 200, 400, 800 and 1600 lines of resolution. Imagine a
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spreadsheet of 400 columns, as thats normal for most PdM programs. The height is normally 1
Volt with a resolution of 0.005 and automatic scaling. Time waveform data are broken down into
frequency spectra. So, each of the 400 windows has amplitude: that amplitude for each window is
squared. Overall level (OA) is the square root of the sum of the squares. It is the sixth band in my
PdM software. Or in a 200 line analyzer it would be line 201.
New subject: In the US we use g's 0-P but in Europe they use mm rms or g's rms which is totally
foreign to us. I did not mention it at all. In addition, CSI boxes used a notation of rms on their box
but the output was really 0-P - not rms. It was a flaw in their box, but better not go there.
In this world, people in vibration should realize that integration from g's to IPS (in/sec) isn't
absolute but only retaliative. The universal language is IPS but the analytical world is better if kept
in tune with the type of transducer one is using. Acceleration - work in g's. Velocity transducer -
work in IPS. Eddy current probes - work in mils. But, translate to common terms when reporting.
MEASUREMENT PARAMETERS: Acceleration, Velocity, Displacement and Acoustics (dB).
There are contact type and non-contact type. Which is best? That may be impossible to
determine. Large turbo machinery both. The contact type are cheaper and easier as a rule but
are affected by the machines dampening effect caused by bearing type and mass. Mass
determines resonance so the sensors mass should be so that the frequencies of interest are
below its natural frequency. The non-contact sensor (eddy current probe) provides rotor dynamics
and good down to DC. We are not getting into all systems, laser, all non-contacting as this is only
a field reference book.
Bearing cap data are now taken almost exclusively in acceleration. Ive used that approach since
1980 exclusively. A velocity transducer is sometimes useful for balancing, apart from that I wont
use a velocity transducer and dont integrate an acceleration spectrum into velocity or double
integrate to a displacement spectrum. Those integrations are only relative, not absolute. I will and
do present digitized data in all three parameters for some. I do not believe in producing a velocity
spectrum because it is so limited as compared to an acceleration spectrum. Velocity (IPS) is a
good language to translate into words and is a common language as it is irrespective of
frequency. So, you can iterate an amplitude and one can understand its magnitude or severity.
4
.
A picture is worth a thousand words. You cant analyze what you cant see. Why waste your
time with a velocity spectrum when it isnt even a true integration from acceleration to velocity.
Integration is relative, not absolute. Work in acceleration and get used to it; its the right thing to
do now and the way of doing in the future. It took some transition period to get from displacement
to velocity. Machines fitted with anti-friction bearings should always be monitored in acceleration,
and use acceleration spectra for diagnostics: 3600 RPM to 5 kHz. Likewise, if Im using a velocity
transducer or an eddy current probe I monitor IPS and mils respectively never integrating the
spectra only displaying digitized data in all three parameters.
Both displacement and acceleration are respective of frequency, therefore velocity is the
language to speak in for clarity and ease of understanding. But in the analysis stage when
gathering acceleration data use acceleration for analysis. Discipline yourself and youll find over
time your PdM program will evolve into planned scheduled maintenance and youll get maximum
life from the machine and eliminate overtime. I have successfully implemented such programs.
Youll tear into a machine and realize that you have gotten maximum life: no need to pull the
magnifying glass out and look for scratches. Ive seen people do that it stands out that its an
excuse for inability or a poor program.
Relationships of sinusoidal velocity, acceleration, & displacement
ENGLISH METRIC
V=(Pi)fD V=(Pi)fD
V=61.44 g/f V=1.56 g/f
g=0.0511f
2
D g=2.013 f
2
D
g=0.016 2Vf g=0.64 Vf
5
D=0.3183 V/f D=0.3183 V/f
D=18.57 g/f
2
D=0.4968 g/f
2

NOTE: D= inches pk to pk or meters pk to pk
V= inches per second (IPS) meters per second
f= frequency in Hertz (Hz) or cycles per second (RPM/60)
g= 386.1 IPS
2

Constants for true sine waves only

rms value = 0.707 X peak value avg rms
rms value = 1.11 X avg value
peak value = 1.414 X rms value
peak value = 1.57 X avg value
average value = 0.637 X pk value P-P
pk to pk value = 2.0 X pk value

Microphones (acoustics) are not usually associated with machines except for OSHA sound level
measurements.
But, if you have a machine high and away and dont have transducers mounted, then a highly
directional microphone can assist for frequency analysis.
This will sometimes produces good results and always is better than no approach or program at
all.
6

Sound isnt our topic although sound is vibration and vibration is sound. We wont be getting into
media that has so many variables and dampening factors and background noise etc. But, heres
a chart nonetheless.
7

In a PdM program we normally are concerned with bearing cap data and sometimes with
permanently installed transducers. However, one must know that the transducer is in calibration.
An outside consultant may choose to use known transducers such as his or her own
accelerometers for bearing cap data. Normally, (for example) I will go into a control room and
acquire data directly from the panel by plugging in to an existing system such as a Bentley
Nevada 3300; this gives me rotor dynamics. But, I also acquire bearing cap data.

NOTE: A normally good machinery analyses instrument system will cover 20 kHz to 0 Hz or DC
and have transducers covering 0.05 Hz to 20 kHz.
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They may be phased matched having phase measuring capabilities down 30 RPM within 2%.
Phase gathering triggering devices either photo tachs, laser, eddy current probes or strobes. Set
transducers side by side to confirm amplitude/phase integrity as a field check.

High quality tachometer may be necessary when phase readings arent stable using conventional
phase gathering instruments.
OUT OF BALANCE CONDITION: Imbalance occurs at running speed and produces a clean
sharp spike at 1X. Running speed vibration is very often misunderstood and gives many
technicians problems. Ive seen technicians attempt to balance rotors with high 1X and almost
nothing else - no 2X or 3X and relatively smooth the rest of the base band. Misalignment (gross)
will totally manifest itself in 1X and youll play havoc attempting to balance that problem. Bearing
problems and faulty machine parts will manifest themselves into running speed vibration at some
percentage as the machine deteriorates. That percentage may be very small but a bearing flaw
(for example) will produce drag and contribute some magnitude into running speed though its
source may not be determined. Analyze the spectra, different data points, and different positions
with phase data. Correct faults then balance. All too often I see technicians balance and
amplitude at running speed will become acceptable and itll be called good. However, that
balance job didnt magically cure the machine component that also has a fault.
Never just balance a machine to an acceptable vibration level and walk off with out some analysis
to determine machine condition. Imbalance in vertical machines is usually highest transverse to
the flow or in the most flexible direction. Bottom mounted machines usually reveal higher 1X
vibration in the horizontal direction.
Once imbalance has been determined to be the fault, balance the number of planes necessary to
achieve smooth machine operation.
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When field balancing one may want to use eddy current probes or existing transducers. Most
large turbo-machinery will have a permanent monitoring system installed that you can plug into in
a control room or local panel.
On paper machine dryer cans where you balance two planes and still have excessive amplitude:
does the phase match - yes, then whip is the problem and requires third plane balance or further
testing. The third plane is the center of the roll.
1X vibration problems. These are imbalance, resonance, bent shaft, external mechanical run-
outs (coupling hub, pulley, etc., machine part, electrical, eccentrics) internal run-outs.
Phase measurements (see photos below) are very useful in determining misalignment and bent
shaft but one of the easiest methods of detective work is to simply shut down the machine when
you can and if practical. This enables you to monitor power off cascading to a complete stop. Use
a good analyzer with capturing capabilities or a tape recorder when you can.
Often the vibration disappears upon power off if electrical in nature. By monitoring coast down
one may record via instrument tape recorder, or internal capture in a real time analyzer,
information that can identify resonance. Once the machine is shut down, physical measurements
can be taken; such as shaft run outs, coupling run outs, alignment, etc. On electric motors you
may find a chipped blade on its fan. A problem can be simple too.
Strobe for phase and/or motion study.

Photo tachometer for once per sync or
trigger.

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VIBRATION GUIDELINE CHART
Frequency Probable Cause Other Possible Causes
Running Speed (1X) Imbalance
Misalignment
Bent Shaft
Resonance
Eccentric journals, gears or pulleys
Reciprocating forces
Electrical
Two Times or
First Harmonic
(2X)
Mechanical
Looseness
Misalignment; high in the axial direction
Reciprocating forces
Resonance
Loose bearing or part
Second Harmonic
(3X)
Misalignment
(shaft to shaft)
Excessive axial clearance
Electrical; air gap
Internal misalignment
Machine part
Fourth 4X Coupling Problem
This phenomenon occurs with coupling problem, but can also be bearing
looseness
Resonance possibility in slower machines
Machine part
Fifth 5X Machine Part
Vane pass in pump
Excessive clearance
NOTE: Single volute pumps usually 3 or 5 vanes. Double volute pumps have even number of vanes. Non-clog pumps normally
have two vane impellers. Pumps should have 12% cut water clearance so cavitation can be avoided.
Sixth 6X Machine Part
Vane passing
Rotor slippage on shaft
(usually found with 4X)
Sub-rotative
43% typical
can occur @
39%-48%
Oil Whirl
Lubrication
Oil Whip
FTF Fundamental Train Frequency
Half Running
Speed 1/2X
Rub
In a sleeve bearing - rub (0.01 IPS)
Resonance Drive Belts
Drive Belts
Defective machine parts
Line Frequency
60 Hz
Electrical
Rotor Bar Problem
Eccentric rotor
Unequal air gap
Unbalanced phases
Insulation Breakdown
Line Sync Frequency
120 Hz
Rotor Problem
Rotor resonance
Torque pulses
Upper Harmonic
Frequencies
Gears
Gear wear, look for side bands of defective shaft speed
Fan speed x # blades (Aerodynamic)
Cavitation, impeller x # vanes (Hydraulic)
Machine part
Upper Frequencies
not Harmonic
Bearing Defects
Lubrication
Inner race - BPIR
Outer race - BPOR
Ball Spin - BSF
Cage - FTF
Synchronous 2 pole motors operate @ 60 Hz (3600 RPM): A good real time analyzer may have a resolution of 0.0039 Hz or
better with a dynamic range of 120 dB - good for analysis when a fault is detected: A must for third party consulting. Traceable to
the NIST is a requirement.

11

OK, how do we check and solve for these problems?
Lets go to misalignment; it is usually associated with a 2X component along with 3X in the axial
direction. However, gross radial misalignment will manifest itself in 1X and not even show 2X or
3X. Angular misalignment is usually found at 2X in the axial direction. Using phase as a tool
measure both ends and across the coupling. When searching for an unknown source, dont form
an opinion before youve gathered sufficient data. Ive seen people try fruitlessly to balance a
misaligned machine. It happens too often. Of course a good maintenance program will have
alignment records. And those alignment records should be truthful and exact so they can be used
for an analysis tool. If physical measurements must be taken one may do so if the situation
permits.
Use good field proven techniques and procedures to gather alignment data and/or correct
alignment.

Bentley Nevada Alignment instrument FixturLaser/Vibralign Dual Beam
The procedures that follow are for all types of alignment. These are field proven and work. They
will enable you to align in the shortest period of time. The types of alignment are: Indicator
Reverse, Long Spacer Coupling and Rim & Face. The methods for these types are: Laser (single
and dual beam), dial indicators, parallels and micrometers.
12

Of course this one with the big picture is my personal kit (shims are extra): PdMK-2.
Visit http://www.pdm-engineering.com

13
ALIGNMENT PROCEDURES
!SAFETY; lockout and tag. Rack out fuses and chain valves when necessary
!Ensure driven machine has no stress from piping or soft foot and that the anchor
bolts are tight
!Inspect the feet and base of the machine to be aligned for burrs, roughness, dirt
!Evaluate if a temporary spacer is need or useful for this alignment process; note
!Inspect coupling and check for run outs
!Coupling halves must if possible rotate together for dynamic alignment
!Evaluate method of alignment to be used
!Which is best suited for this job
!Is axial thrusting a factor
!Collect SAG data and record
!Install brackets on machines and record machine dimensions
!Check for soft foot; correct as necessary
!Rough align within 1/16 inch
!Record alignment readings
!Are they valid?
!Mathematically correct and repeat?s thrust a consideration?
!Calculate shim and lateral shift change
!Via computer? Print and file.
!Calculator? Record, plot and file.
!Make changes and verify & PLOT
!If spacer was used, remove it at this time
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!PLOT THE FINAL ALIGNMENT DATA
!UNLOCK AND REMOVE TAGS; NOTIFY OPERATIONS
!PLACE RECORD AND PLOTS IN MAINTENANCE FILE
2X running speed - mechanical looseness is a prime factor when this type of vibration occurs. It is
radial in nature and usually predominate in the vertical direction. It sometimes pays to acquire
data at the foot or split of a bearing cap. Reciprocating forces; are you analyzing a compressor?
If you are fortunate enough to have a good vibration lab, you can duplicate most vibration
situations or create experiments for further study. Bentley Nevada markets a good lab kit
complete with eddy current probes and oil whirl attachment.

Measurement techniques are important as well as applying common sense. Approach the
machine like a crime scene. Notice everything; does the foundation appear correct and properly
isolated? Are there cracks on the Floor; stand on each side of the crack - is there a difference -
measure? Can you feel or hear a beat? Use a stopwatch, count the beats over a five minute
period. Ive uncover the source of vibration using this technique. Peck on a sole plate, is there
thud? Are there splits in the case or bearing housings - measure both sides. Eddy current probes
give rotor dynamics, but also take cap readings.

Cap readings make up machine and rotor movements. Is there a difference from machine to
base? What about phase end to end, radically? Phase axially: measure every ninety degrees.
In low frequency problems, resonance is usually a consideration. Can you alter speed or other
factors? A coast down provides good information. While the unit is down, perform ring testing -
this will give you natural frequency. One problem can excite another.
15

Another consideration in taking low frequency measurements; low pass filters. Theyre available
in a variety of ranges. Low pass filters can let you blow up low frequency signals. This works well
especially with an analyzer having a 90 dB range or better. Also real time zooming is a good tool.
This can give a resolution of 0.0156 Hz or better; very good to separate frequency components.
Sixty Hertz from running speed; side bands around 60 Hz such as around 1.2 Hz delta freq and
so on.
While were in low frequency stuff, lets consider half running speed. A rub in a sleeve bearing will
show up at and may be very severe at 0.03 IPS (inches per second).
What is a machines mass, dampening factor? A rub at 0.05 IPS is trouble. Also look for sub-
harmonics. In reality; you never want to see a rub.
Sleeve bearings: rubs, excessive clearance, misalignment, lubrication and looseness are main
concerns. Since these bearings ride on a film of oil and the hydraulic pressure provides certain
lift, clearance is an important function. Excessive clearance will cause harmonic content. Oil whirl
is - a riding up and slipping back on the journal; when it becomes violent it is called whip. Oil
viscosity is an important factor and one must consider the type of oil system.
We have oil bath, oil circulation, ring oiled, mist lubed; etc. Lubrication usually isnt a big problem
anymore. I once encountered an oil whirl in a machine with five tilting pad bearings. If a sleeve
bearing is loose in its housing it can produce a 4X component; make sure the 4X isnt being
produced from another source. Again, always consider a phase study.
The fifth and sixth harmonic (5X & 6X); machine parts and looseness are main contributors but,
the 6X can be generated by a loose rotor and is usually accompanied by 4X. You may have
never seen this in print before, but this comes from practical experience. Just like the
misalignment condition manifesting itself exclusive in 1X. Physically setup that condition in a
machine and let it prove itself.
I made this statement in 1983 about acceleration; within ten years everyone will work in
acceleration. Velocity will only be used as the universal language and rightly so. However, you
cant argue with success; if youre using velocity successfully and almost only worked in velocity:
give acceleration a try. Back in 1980 velocity was the new kid on the block for most. I think youll
be glad you switched. Id rather fight than switch back. There was also a transition period
between displacement and velocity. Who works in mils today for a PdM program? Remember,
acceleration is the right thing to do: integrating to velocity is not absolute only relative. There is no
pure integration and you cant analyze what you cant see.
16
Anti-friction bearings: use both time waveform and frequency spectra. These bearings transmit
forces more readily than sleeve bearings and the stiffest direction usually reveals a higher
magnitude of vibration. Banding analysis and overall level diagnostics work well.
On 3600 RPM machines use a base band of 5 kHz. For purposes of resolution I normally view 2
kHz as my primary base band. But, never limit anything when troubleshooting. Defective anti-
friction bearings are a product of mechanical deterioration. When this occurs, a sharp spike will
broaden: study spectral shape and use shape as a diagnostic tool. Overall analysis is also useful
but always with the frequency spectra. Windowing as in different base bands is also a tool.
Theres more than just the Hanning window too. Explore! Technical Associates of Charlotte have
a good section on A-F bearings; R-0792-3, page 2. A good analyzer is a very valuable too. Just
any ole black box wont do. Theres more than shown.

This has been the common analytical approach since the late 70s. A word of warning; spike
energy is not a good evaluation parameter, never rely on it for a tool. And, it isnt good at all on
low frequency machines; i.e.. paper machine dryer cans. On high RPM machines note the
harmonics of bearing fundamentals. Another factor of detrimental high frequency vibrations
related to A-F bearings - shaft currents. This can be measured (shaft currents) with a good DMM.
You can also have a buildup of static current that discharges through the bearing. Again, use 5
kHz base band on 3600 & 1800 RPM machines in conjunction with your normal observance
frequencies. If magnitudes of vibration are observed near the end of the spectra (high frequency
region), then you may want to look at the next higher base band on your analyzer.
With the absence of machine defects, bearing defects having a magnitude of 4-7 gs 0-P over 5
kHz are nearing failure. This is a broad statement, mass & dampening must be taken into
account. Example: 5 gs 0-P over 5 kHz @ 3600 RPM usually will fail within a month; maybe a
little less, maybe a little more.
But, the same machine situation @ 1800 RPM may take two months to fail plus or minus a little.
Please, this is an illustration, so dont hold me to exact numbers although the scenario is close. In
PdM program mode use trending, if the program is old enough. Continuous monitoring systems
provide good trending information much better than a monthly or quarterly route program.
Monthly or quarterly monitoring programs require a good chief analysis. Trending is valuable on
continuous monitoring programs but has short comings on anything less.
17
Lastly, lubrication or lack of it. Check schedules, quantity per time interval, type, etc. A bearings
natural frequency will be excited in the absence of lubrication. Lubrication makes the wheels go
around. Alignment makes them run longer, PdM makes them cost efficient.
Got a lube program? Your grease guns should be labeled one shot equals so many grams!
Each grease lubed bearing should be given and exact quantity over a given time interval (i.e. 28
grams per month; 14 grams per two weeks). Classify machines as to speed and environment to
determine frequency of lubrication. Lubrication is your single most important program; not
alignment or balancing or PdM. I have papers Ive written on grease lubed bearings and
quantities per given time interval. I like to calculate that time/time interval as accurately as
possible. If I have a good PdM program it will fine tune those numbers. Therefore, when a good
PdM program is in place one can know when the lube is lacking. With this in mind; calculations
and estimations can be backed off slightly and fined tuned over time through frequency analysis.
Gearboxes: These can be very complicated; I dont consider any to be categorizes as simple.
Correct gearbox set up is essential. It sometimes becomes necessary to stress a gearbox to
achieve internal alignment. I was call on a very high H.P. unit operating at 12.0 gs 0-P @ gear
mesh. Upon shut down I inspected and measured clearances. There was originally internal
misalignment. But, it had already worn a pattern. I recommended to continue operation as
distorting the case to correct internal misalignment would only cause an increase in vibration
level. They opted to distort the case. Vibration increased. I again recommended no action as it
would now wear a new pattern and reduce in magnitude. It was left there and monitored regularly.
At 18.0 g it was inspected and then put back in service to 20.0 gs. This is unusual but not odd.
Always use time waveform as an analytical tool. The defective gear will be modulated or side-
banded by the defective gears shaft speed. Also, look for a small `side spike on the side of
defect peak in time waveform if a gear is cracked or chipped.
A voith coupling (high H.P.) may give you a bit of diagnostic problem as they can have an
amplitude/frequency display in an axial position that appears excessive. But, Its a characteristic
of that box.

Some of these things are only obtained from experience or being around someone with
experience. In troubleshooting always draw on all natural resources available to you.
I believe thats a good philosophy in most all aspects of everything you do. Gear mesh frequency
in most cases is in trouble at or around 10.0 gs (high frequency). Also, look for half gear mesh.
How is the fundamental affected? Use phase.
Sometimes you are put in a position of doing diagnostics above your head. If you gotta, you gotta:
get your feet wet. But, a critical, costly machine?
Maybe its time to call the outside consultant, who? Again, these are guidelines to help you
troubleshoot and solve your problem. Know when its time to call in help. I have developed these
18
19
standards with and through others: The chief analyst must have at least ten years experience as
an analyst with five years spent as an outside consultant. It shouldnt insult him if you ask for a
resume and sample report as well as references. Is it warranty work; then the work must be
traceable to the NIST, formerly The National Bureau of Standards, now, National Institute of
Standards and Technology.
I have developed standards for acceptance of pumps & motors, plus specifications for motor
rebuild shops.
On a last note; dont over look the simple. Calibrate using a level, check calibration. Alignment
check calibration before every job: Indicator Reverse, Long Spacer Coupling, Rim & Face and
especially Laser. Using a micrometer check against a standard before using.
The materials in this field guide were supplied by:
SAM PICKENS; PdM Engineering
PO Box 23494 Macon, GA 31212-3494
Phone 678-772-3166 Fax 386-684-4068

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