Chapter 2

VIBRATION ANALYSIS APPLICATIONS

The use of vibration analysis is not restricted to predictive maintenance. This technique is useful for diagnostic applications as well. Vibration monitoring and analysis
are the primary diagnostic tools for most mechanical systems that are used to manufacture products. When used properly, vibration data provide the means to maintain
optimum operating conditions and efficiency of critical plant systems. Vibration analysis can be used to evaluate fluid flow through pipes or vessels, to detect leaks, and to
perform a variety of nondestructive testing functions that improve the reliability and
performance of critical plant systems.
Some of the applications that are discussed briefly in this chapter are predictive maintenance, acceptance testing, quality control, loose part detection, noise control, leak
detection, aircraft engine analyzers, and machine design and engineering. Table 2.1
lists rotating, or centrifugal, and nonrotating equipment, machine-trains, and continuous processes typically monitored by vibration analysis.

Table 2.1 E ~ M

and Procasa ~ p i c a ~ Mo.itorat by Wbration Analysis

CentHflqlal

Reciprocating

Continuous Proeess

Pumps
Compressors
Blowers
Fans
Motor/generators
Ball mills
Chillers

Pumps
Compressors
Diesel engines
Gasoline engines
Cylinders
Other machines

Continuous casters
Hot and cold strip lines
Annealing lines
Plating lines
Paper machines
Can manufacua~g lines
PicHe lines
continued

Vibration Fundamentals

Table 2.1 Equipment and Processes I~ypimlly Monitored by ~ n

Product rolls
Mixers
~xes
Centrifuges
Transmissions
Turbines
Generators
Rotary dryers
Electric motors
All rotating machinery

Boring machines
Hobbing machines
Machining centers
Temper mills
Metal-working machines
Rolling mills, and most
machining equipment

Analysis

Printing
Dyeing and finishing
Roofing manufacturing lines
Chemical production lines
Petroleum production lines
Neoprene production lines
Polyester production lines
Nylon production lines
Flooring production lines
Continuous process lines

Source: integrated Systems, Inc.

PREDICTIVEMAINTENANCE
The fact that vibration profiles can be obtained for all machinery that has rotating or
moving elements allows vibration-based analysis techniques to be used for predictive maintenance. Vibration analysis is one of several predictive maintenance techniques used to monitor and analyze critical machines, equipment, and systems in a
typical plant. However, as indicated before, the use of vibration analysis to monitor
rotating machinery to detect budding problems and to head off catastrophic failure is
the dominant predictive maintenance technique used with maintenance management
programs.

ACCEPTANCETESTING
Vibration analysis is a proven means of verifying the actual performance versus
design parameters of new mechanical, process, and manufacturing equipment. Preacceptance tests performed at the factory and immediately following installation can be
used to ensure that new equipment performs at optimum efficiency and expected lifecycle cost. Design problems as well as possible damage during shipment or installation can be corrected before long-term damage and/or unexpected costs occur.

QUALITY CONTROL
Production-line vibration checks are an effective method of ensuring product quality where machine tools are involved. Such checks can provide advanced warning
that the surface finish on parts is nearing the rejection level. On continuous process lines such as paper machines, steel-finishing lines, or rolling mills, vibration

Vibration Analysis Applications

analysis can prevent abnormal oscillation of components that result in loss of

product quality.

LOOSE OR FOREIGN PARTS DETECTION

Vibration analysis is useful as a diagnostic tool for locating loose or foreign objects in
process lines or vessels. This technique has been used with great success by the
nuclear power industry and it offers the same benefits to non-nuclear industries.

Nots:: CONTROL
Federal, state, and local regulations require serious attention be paid to noise levels
within the plant. Vibration analysis can be used to isolate the source of noise generated by plant equipment as well as background noises such as those generated by
fluorescent lights and other less obvious sources. The ability to isolate the source of
abnormal noises permits cost-effective corrective action.

LEAK DETEC11ON
Leaks in process vessels and devices such as valves are a serious problem in many
industries. A variation of vibration monitoring and analysis can be used to detect leakage and isolate its source. Leak-detection systems use an accelerometer attached to
the exterior of a process pipe. This allows the vibration profile to be monitored in
order to detect the unique frequencies generated by flow or leakage.

AIRCRAFT ENGINE ANALYZERS

Adaptations of vibration analysis techniques have been used for a variety of specialty
instruments, in particular, portable and continuous aircraft engine analyzers. Vibration
monitoring and analysis techniques are the basis of these analyzers, which are used
for detecting excessive vibration in turboprop and jet engines. These instruments
incorporate logic modules that use existing vibration data to evaluate the condition of
the engine. Portable units have diagnostic capabilities that allow a mechanic to determine the source of the problem while continuous sensors alert the pilot to any deviation from optimum operating condition.

MACHINE DESIGN AND ENGINEERING

Vibration data have become a critical part of the design and engineering of new
machines and process systems. Data derived from similar or existing machinery can
be extrapolated to form the basis of a preliminary design. Prototype testing of new
machinery and systems allows these preliminary designs to be finalized, and the
vibration data from the testing adds to the design database.