Examining Causes

of Pump Vibration
Component failure can occur when pump vibration is not eliminated

M
any vibration problems are a result of rium point. Simply stated, any object that moves back
interactions among a system’s pump, and forth is vibrating. Examples of vibration include
motor, fluid, piping, and structure. a clock’s pendulum in motion, a guitar string that has
This interactive relationship requires a systems been plucked, or a tuning fork that has been struck.
approach to vibration analysis, rather than the These examples use oscillation—or vibration—
investigation of individual compo- to obtain a desired result. However,
nents. Neglecting important factors By STAN KUTIN vibration in a centrifugal pump can be
during pump installation can lead ITT Residential & Commercial Water undesirable and lead to component
to vibration issues that are expensive Morton Grove, Ill. failure.
and time-consuming to resolve. All Vibration is an indication of a
pump installations must adhere to manufacturers’ pump’s condition. All pumps vibrate at some level of
recommendations for system-vibration problems to intensity throughout their life cycle. A vibration
be avoided. However, if a vibration problem occurs, analysis can help identify normal vibrations that
all field and vibration data must be analyzed to may not be harmful as well as vibrations that exceed
determine the cause. Once identified, the correct, acceptable levels and can shorten a pump’s life.
most cost-effective solution can be applied to Because an analysis also may determine the source
eliminate or minimize the vibration. or cause of a vibration, it can be used as a tool for
troubleshooting and preventive maintenance.
What is Vibration?
Vibration is defined as mechanical oscillations or What Causes Vibration?
the repetitive motion of an object about an equilib- Able to originate internally or externally, an exci-
tation force is the only cause of vi-
bration. Repeating forces create the
vibration problems most commonly
associated with centrifugal pumps.
These forces often are caused by the
rotation of imbalanced, misaligned,
or worn pump components.

How is Vibration Measured?

Vibration measurements should
be taken at the inboard and out-
board bearings of a pump and

A senior product specialist in the

commercial HVAC pump group
for ITT Residential & Commercial
Water, Stan Kutin has experience
with HVAC-system design, applica-
Vibration measurements should be taken in vertical, horizontal, and axial tions, and centrifugal pumps. He can
directions. be reached at stan.kutin@itt.com.

2 April 2009 • HPAC Engineering

motor in axial, horizontal, and verti-
cal directions. If a more intensive
analysis is required, measurements also
should be taken at several places on
the pump base. Electronic probes or
sensors can be attached at each of
these locations, sending electronic
signals to a vibration analyzer. Mea-
surements should be taken at operating
speed for constant-speed motors and at
varying speeds for pumps operating on
variable-speed drives.

How is Vibration Described?

Vibration analyzers convert complex
mechanical movements into equivalent
electrical signals that can be filtered and
measured using efficient algorithms.
The resulting spectrum can describe
each vibration by frequency, ampli- Points for axial and vertical measurements on a pump’s inboard bearings.
tude, and/or phase and used to identify
the root cause of a pump’s vibration. tions simply are a multiple of funda- Displacement amplitudes are used at
Confirmation of a vibration source is mental frequency. very low vibration frequencies, typically
critical to any major corrective action Amplitude. Amplitude describes below 600 cpm (10 Hz). High displace-
based on a spectrum. the severity of a vibration and can be ment amplitudes at low frequencies can
Frequency. Frequency describes the measured and expressed as: cause a considerable amount of stress
oscillation rate of vibration or the • Displacement, the total distance damage to a pump. Mounting bolts
speed at which an object vibrates. It is a traveled by a specific component can snap; concrete bases, foundations,
measure of the number of complete during one complete cycle. It measures and grout can crack; and base welds
cycles that occur in a specified period of the magnitude of the oscillation and can fail.
time, such as cycles per second (cps)— can cause stress damage to components. • Velocity, the maximum speed of
also measured in hertz (Hz)—or cycles
per minute (cpm). Using cpm to
describe vibration frequency allows it to
correlate to the rotational speed of the
pump, which typically is expressed in
revolutions per minute (rpm). If pump
speed is 1,800 rpm, and vibration
frequency is 1,800 cpm, frequency can
be expressed as:

1 × rpm

If pump speed is 1,800 rpm and

vibration frequency is 3,600 cpm,
frequency can be expressed as:

2 × rpm

The rotational frequency of a pump

typically is referred to as the system’s
fundamental frequency. Many vibra- Points for horizontal and vertical measurements on a pump’s inboard bearings.

HPAC Engineering • April 2009 3

 P Ump v i b r a t i o n
applications
& resources
PUMPING & PIPING
A point for vertical measurement on a motor’s inboard bearing.
a component during a complete cycle.
Velocity amplitude gives the most
useful information regarding a pump’s
condition. It is a direct indicator of
fatigue because it factors in displace-
ment and frequency. Velocity ampli-
tude measures how often displacement
is applied. After a period of time, the
component simply wears out because
of repeated oscillation. Fatigue failures
typically occur at vibration frequencies
between 300 cpm (5 Hz) and 120,000
cpm (2,000 Hz). Therefore, if frequen-
cies are within this range, velocity-
amplitude measurements are recom-
mended. Fatigue failures occur with
pump and motor shafts, couplings,
bearings, and bases.
• Acceleration, the force(s) causing
oscillation. It shows how quickly ve-
locity changes from one extreme point
to the next. Acceleration amplitudes
are used when vibration frequencies
are above 120,000 cpm (2,000 Hz).
Large forces can occur at high frequen-
cies even though velocity and displace-
ment amplitudes are small. Excessive
acceleration amplitudes can deform the
surfaces of ball bearings and races to the
point of failure. Large forces can break
down the lubricating film in bearings,
4 April 2009 • HPAC Engineering
also resulting in failure.
Phase. Phase establishes the position
of a component oscillating at a given
instant with reference to a fixed point
or another vibrating component.
Simply put, phase lets us compare the
relative direction of movement of a
specific component. Phase is impor-
tant because it determines how vibra-
tions interact—whether they are act-
ing with or against each other. If two
vibrations occur at the same frequency
in a synchronized manner, they are “in
phase.” If vibration frequencies are not
synchronized, they are “out of phase.”
Vibration analyzers and data-collecting
equipment typically use a strobe light
or digital input to display the phase of
a vibration. Determining the relative
motion of pump components reduces
the number of vibration causes and
helps pinpoint problems.
Vibration Limitations
The Hydraulic Institute (HI) pub-
lishes recommended vibration limits for
a variety of centrifugal pumps. Limits
are based on the pump type, mounting
configuration, fluid, and horsepower
required. Values for each style of pump
are described using velocity amplitudes
and should be used as general bench-
marks. Field vibration amplitudes at
or below these limits will not affect a
pump’s life or reliability. Vibration
amplitudes above HI recommendations
should be investigated to determine
the vibration’s cause or monitored for
changes. Exceeding maximum limits
may be acceptable if the amplitudes do
not increase over time and there is no
sign of component damage or increased
noise levels.
HI’s recommendations are based
on several critical assumptions. First, a
pump must be operating under steady-
state conditions at its rated speed with
no cavitation or air entrainment. A
straight, uniform flow of fluid into
the pump is required. Piping should
be anchored adequately to avoid any
strain on pump flanges. Couplings and
components must be aligned to the
manufacturer’s specifications. Finally,
the foundation must have adequate
mass and rigidity, and the pump base
should be properly leveled, anchored,
and grouted (if required).
Pump installations that fail to meet
these assumptions may exhibit vibra-
tion problems immediately at startup
or after many hours of operation. HI
assumptions are addressed in most
pump manufacturers’ installation
manuals and should be followed during
installation.
HI recommends limits on pump-
rotor residual imbalance. International
Organization for Standardization
(ISO) balance-quality grade (G) 6.3 is
used for rotating components to ensure
imbalance is kept to a minimum. Impel-
lers, couplers, and rotating assemblies
often are balanced to G6.3 to achieve
optimal balance based on rpm. G6.3
allows a certain displacement from
centerline vs. rpm. At 1,800 rpm,
the allowable residual imbalance is
1.2 times 10-3 in. per unit of rotor mass.
If increased to 3,600 rpm, the accept-
able residual imbalance decreases to
0.7 times 10 -3 in. per unit of rotor
mass.

Impellers typically are balanced to
G6.3 standards after they are trimmed
to the correct diameter. If trimmed
in the field, the impeller should be
balanced again to meet G6.3 standards.
Failure to rebalance an impeller could
cause a vibration issue.
Causes of vibration
Typical 1-times-rpm vibrations
include imbalance, a soft foot, and a
bent shaft. Mechanical looseness,
misalignment, and resonance can
generate vibrations at frequencies of
two, three, or more multiples of rpm.
Failing bearings typically produce
non-integer multiples of pump speed.
Hydraulic oscillations show frequen-
cies that are a product of the number of
impeller vanes multiplied by rpm.
Vibration frequencies are used to
help locate the root cause of a pump’s
excessive vibration. Knowing the vibra-
tion frequency—the first step in the
analysis process—can help narrow the
possible causes of vibration.
Misalignment. Misalignment is
the No. 1 contributor to vibration
problems. This occurs when rotating
centerlines of two shafts are offset and/
or at an angle. Thus, proper coupling
alignment is key to avoiding vibration
problems. Shaft alignment should
occur several times during a pump
installation. Initial alignment should
be completed prior to the piping
of a pump. After piping is complete
and the pump base is anchored (but
not grouted), the shafts should be
aligned again. The final shaft alignment
always should be performed under
actual operating temperatures. This
allows for the contraction or expan-
sion of all system components and
ensures proper alignment under actual
operating conditions. Alignment
should be checked periodically and
corrected if needed. Running a mis-
aligned pump can cause extreme heat in
couplings and bearings, bent shafts, and
increased operating costs. To reduce
angular misalignment, consider dial
p u mp
A point for horizontal measurement on a motor’s inboard bearing.
indicators or laser alignment equip-
ment.
Coupling manufacturers publish
alignment tolerances that should
be followed if not addressed in a
pump’s installation manual. Different
couplings will produce different
vibrations, which are characteristics of
design and construction materials.
Soft foot. Vibration also can be caused
when the feet on a motor frame or
pump casing are not on the same plane.
Tightening the nut and bolt on a soft
foot can distort the base, casing, and/or
motor frame, leading to vibration. This
is similar to pipe strain on suction and
discharge flanges, which can induce a
soft foot. Pump and motor shafts can
be aligned perfectly and still exhibit
excessive vibration because of the
distorted frame caused by a soft foot.
To check for soft foot on a mo-
tor frame or pump casing, loosen
the mounting bolt for each foot
individually, checking the vibration
level after each change. If a soft foot
has occurred, the vibration level will
decrease as a mounting bolt is loosened.
Shims can be added under a soft foot
to correct the condition. Alignment
between shafts should be checked after
shims are added.
HPAC Engineering • April 2009
v i b r a t i o n
applications
& resources
PUMPING & PIPING
Imbalance. Imbalance is caused when
an object’s center of mass is different
from its center of rotation. As the
leading cause of pump imbalance,
impellers should meet G6.3 for allow-
able residual imbalance. For high-rpm
pumps, rotating assemblies, including
couplings, should be balanced as a
unit to meet G6.3. It is reasonable to
assume an impeller is balanced at
startup, but after operation, an imbal-
ance may be caused by wear. Impeller
imbalance also is a frequent cause of
mechanical-seal and bearing failure.
Another area of concern for imbal-
ance is the shaft key used for a coupling
and impeller. Using the wrong key
could adversely affect rotating-assem-
bly balance.
Mechanical looseness. Mechanical
looseness should never be overlooked
in the field. All mounting bolts, includ-
ing base-plate, pump, motor, coupler,
and guard bolts, can become loose
over time. Pipe restraints also should
be checked for looseness. Vibration
can result from cracked foundations,
insufficient contact between grout and
pump bases, or cracked grout in base
plates. When these problems occur, a
pump, base, and foundation no longer
are one solid unit. They become several
5
 p u mp v i b r a t i o n
applications
& resources
PUMPING & PIPING
A point for vertical measurement on a pump base.
individual units, each with its own
natural frequency. It is important to
use high-quality non-shrinking grout
when installing a base designed for
grouting.
Base installation. Poor base instal-
lation is another leading contributor
to vibration. Foundation bolts of the
proper size and number should be
embedded in concrete prior to the
installation of a pump base. The base
should be supported and leveled by
properly sized shims at a minimum of
each anchor bolt. Nuts should be set to
the correct torque based on their size.
Any exceptions or modifications to
the pump-base installation can lead to
vibration issues.
Resonance. Every system has many
resonant frequencies. If a system
encounters vibrations at these frequen-
cies, amplification will result in prema-
ture component failure and increased
downtime. Resonance can be avoided
by changing a system’s frequency,
which is determined by the mass,
stiffness, and damping properties of all
of the components involved, including
the pump, base, motor, piping, cou-
pling, guard, foundation, etc. If the
resonance vibration is just below the
6 April 2009 • HPAC Engineering
system’s natural frequency, the stiff-
ness of the system should be increased
so the vibration frequency shifts above
the natural frequency. If the resonance
vibration is just above the natural
frequency, the system’s mass should
be increased, shifting the vibration
frequency below the natural frequency.
Another solution to resonance vibra-
tion is to change the operating speed.
When a centrifugal pump is operating
on a variable-frequency drive, chang-
ing the speed in lieu of the resonant
frequency can be the most economical
option. Drives often are programmed
to skip a frequency or two to avoid
resonance vibration. This should not
be a problem in an HVAC applica-
tion. Another option is to determine
which component in the system is
being excited at resonance, then replace
the component or modify its resonance
frequency.
Cavitation. Cavitation also can cause
pump vibration. It occurs when the
system’s available net-positive suction
head (NPSHa) is less than the pump’s
requirement (NPSHr). Indications of
a cavitating pump can include noise,
fluctuating flow rates, a decrease in dis-
charge pressure, and vibration. Cavita-
tion-induced vibration is caused by im-
ploding vapor bubbles that introduce
shock waves in a pump, shortening the
life cycle of all of the pump’s mechani-
cal components. The components that
commonly fail prematurely are impel-
lers, wear rings, and casings. If cavitation
is present, NPSHa should be increased
above NPSHr by making changes in
the system design or operation to
reduce or eliminate cavitation. Cavi-
tation does not always produce pump
vibration, and the induced vibration
often is random and unmeasurable.
Motors. Finally, motors can be the
root cause of vibration. Like centrifugal
pumps, motors are built to vibration
specifications. Guidelines are given by
the National Electrical Manufactur-
ers Association. Unfiltered velocity
amplitudes should not exceed 0.12 in.
per second zero to peak at bearings
for 1,200-, 1,800-, and 3,600-rpm
motors. These guidelines are for rigidly
mounted uncoupled motors running
at no load.
Electrically induced vibration results
from unbalanced voltage, broken ro-
tor bars, and air-gap distortion and can
be checked by de-energizing a motor
while in operation. If the vibration dis-
appears after the motor is de-energized,
the vibration is induced electrically. A
broken rotor bar prevents current flow,
resulting in a lack of a magnetic field.
Because the magnetic field causes the
rotor’s rotation, its absence in one area
results in an imbalance force. Air-gap
distortion results when the space or gap
between the rotor and stator is not per-
fectly even all of the way around. The
strength of the magnetic field is propor-
tional to the gap. Thus, the magnetic
field is stronger where the gap is small
and weaker where the gap is large. This
variation in the magnetic field around
the rotor also can produce an imbal-
ance. By understanding vibration, its
causes can be identified and corrected.
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