Vibration Analysis

Unbalance
• Amplitude proportional to the amount of
unbalance
• Vibration high normally in radial direction
(may be also in axial direction incase of
overhung and flexible rotors ).
• 1* RPM vibration is greater than 80%
(normally) of the overall reading.

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 Vibration Analysis
Unbalance
• Horizontal and vertical 1* RPM
amplitude should be nearly same,
although it also depends on system
rigidity on the particular direction.
• Other frequency peaks may be less
than 5% of the 1*RPM amplitude
• Phase shift of 90 deg. When sensor
moves from horizontal to vertical.

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 UNBALANCE
• Amplitudes are higher in the radial direction
unless the rotor is overhung
• Phase readings will be stable
• Phase readings will shift 90 degrees when pickup
is shifted 90 degrees (60o to 120o phase
difference is allowable)

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 UNBALANCE
• Operating conditions such as load, flow
condition and temperature affect unbalance
• Balance under normal operating conditions
• Changes in track and pitch angle of fan blades
can result in “Aerodynamic Unbalance”

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 STATIC UNBALANCE

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 COUPLE UNBALANCE

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 QUASI-STATIC UNBALANCE

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 DYNAMIC UNBALANCE

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 Typical Spectrum For
Unbalance

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 BENT SHAFTS
• Caused by:
– Manufacturing errors
– Mishandling during transportation
– “Bow” due to thermal growth
• Rotors can be kinked or bowed

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 Vibration Analysis
Bent Shaft
• High axial vibrations
(Greater than 50% of the radial vibration).
• 1*, 2* RPM normally high.
• Dominant vibration normally at 1* if bent near
shaft center, but at 2* if bent near coupling.
• Axial phase differences will tend towards 180
deg. On the same machine component.
• Axial phase analysis needs to be used to verify
problem and type of bend
• Radial vibration is uniform

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 Typical FFT for Bent Shaft

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 Axial Phase Readings

• Determine axial twisting or planar motion

• Taken at 4 positions around bearing face
• Corrections need to be made for transducer
orientation
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 Identifying a Shaft with a Kink

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 Kink in the Shaft
• Use axial phase measurements to see twisting motion
– 180o difference between top and bottom
– 180o difference between left and right
• Shows 1x rpm peak and possible 2x rpm
• Condition verified with dial indicator
• Appears the same as a cocked bearing, but axial
readings show similar amplitudes around bearing face
for kink

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 Identifying a Simple Bow

• Axial amplitude and phase readings around the

bearing face will be uniform
• Shows 1x rpm peak with possible 2x rpm
• Axial phase readings across the support bearings show
180 degree phase difference
• Correct for orientation of transducer

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 Axial Phase Indicating Planar
Motion from Shaft Bow

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 Vibration Analysis
Eccentricity
• Vibration occurs at 1*RPM of eccentric
component in a direction through centers of
the rotors

• Comparative horizontal and vertical phase

readings usually differ by 0 or 180 deg.

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 ECCENTRICITY
• Produces vibration at 1xrpm of the eccentric
component
• Vibration is highly directional
• Pulleys, gears, and chain sprockets will
show directional vibration acting on a line
between the two centers
• Slow motion studies and dial indicators can
assist confirmation
• Balancing will give only limited success

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Eccentricity Gears and Sheaves

• Gears have variation

in mating force along
centerline of gears

• Sheaves have
vibration along
centerline of driver
and driven pulley

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 Eccentric Armatures

• Eccentric Motor Armature causes

unbalanced magnetic forces

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 Typical Spectrum For Eccentricity

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 MISALIGNMENT
• BIGGEST PROBLEM INITIALLY
• Operating temperature can affect
alignment
– Machines aligned cold can go out when
warm
• Bases or foundations can settle
• Grouting can shrink or deteriorate
• Increases energy demands

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 MISALIGNMENT
• Forces shared by driver and driven (not
localized)
• Level of misalignment severity is
determined by the machines ability to
withstand the misalignment
– If coupling is stronger than bearing the
bearing can fail with little damage to the
coupling

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 ECONOMICS OF ALIGNMENT
9Misalignment Causes Financial loss due to
increased energy demand.

9Exponential Bearing life reduction.

9Causes excessive vibration.

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 MISALIGNMENT AND
BEARING LIFE
Misalignment leads to increase in FORCE.
From Bearing Life Equation:

L10=16,700/RPM(dynamic capacity x load / force)3

= hours of life

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 MISALIGNMENT AND ENERGY
CONSUMPTION
TO CALCULATE SAVINGS:
Measure ampearage before & after
alignment
Get motor data
Find the cost of energy of your plant.
KW=(Voltsxampsxpfx1.732)/1000
Annual savings=8400x kw x cost

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 CAUSES
• Thermal expansion due to a process working
with heat (as with a turbine). Most machines
are aligned cold, then as they operate and
heat up, thermal growth causes them to grow
misaligned.
• Machine directly coupled not properly
aligned.
• Forces transmitted to the machine by piping
and support members.
• Foundation uneven, shifting, or settling.
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 EFFECTS
Misalignment usually causes the bearing to
carry a higher load than its design
specification, which in turn causes bearing
failure due to fatigue. Fatigue is the result
of stresses applied immediately below the
load carrying surfaces and is observed as
spalling of surface metal.

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 DIAGNOSIS
• BY OVERALL VIBRATION
Forces shared by driver and driven (not
localized)
Level of misalignment severity is determined
by the machines ability to withstand the
misalignment
– If coupling is stronger than bearing the bearing
can fail with little damage to the coupling.
• SIGNATURE ANALYSIS
• PHASE MEASUREMENT.

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 Three Types of
Misalignment

• Combination (most common)

• Angular
• Parallel or Offset

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 General Characteristics Of
Misalignment

• High axial vibration at 1x RPM

• Radial vibration is highly directional
• 1X, 2x, and 3x running speed
depending on type and extent of
misalignment
– Angular 1x rpm axial
– Parallel 2x rpm radial (H & V)
– Combination1,2,3x rpm radial and axial
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 Typical Spectrum for
Misalignment

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 Vibration Analysis
Misalignment
Angular Misalignment

• High axial vibration

( Greater than 50% of the radial vibration)
• 1* , 2*, 3* RPM normally high.
• 180 deg. Out of phase across the coupling
• Severe misalignment will generate 1x, 3x, 5x

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 Vibration Analysis
Misalignment
Off-Set Misalignment
• Low Axial vibration in comparison to Angular.
Also shows high radial vibrations.
• 1*, 2*, 3* RPM high. 2* often larger than 1*
• In case of severe misalignment, much high
harmonics (4* - 8*) or even a whole series of
high frequency harmonics will be generated.
• 180 deg. Out of phase across coupling

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 Parallel Or Offset
Misalignment

• Produces a predominant 2x rpm peak in the

spectrum
• Severe condition will produce 2x,4x,6x
• Marked by 180 degree phase shift across the
coupling in the radial direction.

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 Typical Spectrum for
Misalignment

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 Axial Phase Showing
Misalignment

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 Other Types Of Misalignment

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 Vibration Analysis
Misalignment
Misaligned Bearing

• High axial Vibrations

• 1*, 2*, 3* RPM high.
• Will cause twisting motion with approx. 180
deg. Shift top to bottom and side to side in
axial direction.

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 BEARING COCKED ON SHAFT
• Comparative axial phase will show large
amplitude discrepancy and same phase as
kink in bearing

COCKED SLEEVE BEARING

• Rarely causes a problem unless there is
some other exciting force to create radial
vibration and magnifies the misalignment

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 COUPLING PROBLEM
• 3X RPM often responds to a coupling problem, particularly
for a coupling having spacer that is too long or too short. In
this case radial spectrum will indicate a fairly noticeable
3XRPM vibration and in the axial direction will show a much
higher 3XRPM component.
• Gear type coupling can experience coupling lockup where
the frictional force causing the coupling to become a rigid
member. A locked coupling leads to thrust bearing
failure.This mainly affects 1XRPM component.
• A loose coupling likely to produce side-bands around blade
pass or mesh frequencies.

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 DRIVE BELT PROBLEMS
• Determine Belt RPM

Pi x Pulley Diameter x Pulley RPM

Belt RPM =
Belt Length

• Multiple events per revolution cause

harmonics of Belt RPM
• Need good resolution

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 DRIVE BELT VIBRATION
• Sheave Alignment and Eccentricity
• Belts with hard spots, missing chunks,
width variations, deformities, etc...
• Generates vibration at 2x, 3x, 4x rpm with
1x rpm in some cases
• Highest amplitudes in direction of belt
tension

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 Calculating Belt Speed

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Indian 47
 Case Study: Worn Belts

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