324 IEEE TRANSACTIONS
MARCH/APRIL 1985
Vibration Analysis-A Proven Technique
Maintenance Tool
JOHN T. RENWICK
Abstract-Predictive maintenance remains a cost-effective means for a
maintenance department to resolve plant machinery problems and
implement a repair schedule. Quality information is the key factor in
designing a successful predictive maintenance program. A strong basis for
quality information and an effective methodology for using this informa-
tion base are two essential program ingredients. When applied with these
ingredients in place, predictive maintenance using vibration analysis has
achieved meaningful results in successfully diagnosing machinery prob-
lems. The benefits of such programs include not only evident cost
benefits, such as reducing machinery downtime and production losses,
but also the more subtle long-term cost benefits which can result from
accurate maintenance scheduling.
INTRODUCTION
KEEPING MACHINERY and plant equipment in good
operating condition to prevent failure and a consequent
production loss should be a maintenance department's prime
objective. If the department organizes a predictive mainte-
nance program, this goal as well as cost benefits can be
realized. While accurate information at the right time is a
crucial aspect of a maintenance regimen, manual record
keeping can be an overwhelming means to determine critical
maintenance areas. Since a predictive maintenance program is
a full-time job, introducing a computer to perform repetitive
labor-intensive tasks allows a maintenance department to work
more effectively and not necessarily harder. Regardless of the
maintenance program's methodology, certain predictive tech-
niques that have been successful should be practiced routinely.
Vibration analysis is one such technique which is being used to
track machine operating conditions and trend deteriorations in
order to reduce maintenance costs and downtime simultane-
ously.
The increasing utilization of predictive maintenance pro-
grams is largely the result of two key functions: 1) the need to
maintain a competitive edge and 2) the advent of affordable
measurement instruments and computer systeins designed to
detect and diagnose problems in an early stage of develop-
ment. Although many early programs were justified on the
basis that saving one catastrophic failure would pay for the
program, this is no longer as common. Since even these early
programs were found to produce a continuing wealth of
information on a daily basis, a "bread and butter" justification
Paper PID 84-18, approved by the Cement Industry Technical Committee
of the IEEE Industry Applications Society for presentation at the 1984 Cement
Industry Technical Conference, Anaheim, CA. May 21-24, 1984. Manuscript
released for publication July 23, 1984.
J. T. Renwick was with the Shaker Research Corporation Latham, NY. He
is now with Vibration Analysis Inc., 2579 NW 18th Drive, Coral Springs, FL
33065.
P. E. Babson is with the Shaker Research Corporation, 968 Albany-Shaker
Road, Latham, NY 121 10.
0093-9994185/0200-0324$01.00 © 1985 IEEE
ON IN[)USTRY APPLICATIONS. VOL. IA-21. NO. 2..
as a Predictive
AND PAUL E. BABSON
has emerged. Now the reasoning is that a diagnostic monitor-
ing program improves general knowledge of the mechanical
condition of the machinery so that several alternative actions
may be taken based upon that knowledge. These actions are as
follows.
* Maintenance may be planned for scheduled outages so
that repair parts and skilled personnel are available to
perform the needed repairs expeditiously, i.e., keep the
equipment in question from becoming a critical schedule
element in an outage.
* The reverse is true, i.e., maintenance need not be
performed because the system is operating normally with
no indication of distress.
* A machine may continue to operate, even with other ill-
defined symptoms, if confidence exists that the machine
can operate until the next outage either without further
degradation or with adequate warning of further degrada-
tion.
* A machine must be shut down because the diagnostic
indicators warn of impending failure.
The consequences of these actions will vary and require
different levels of confidence to be acquired before a program
may be fully implented. In any event, even as this experience
is being gained, the operator has the advantage of basing
decisions on more information than previously available.
Experience has shown that typically, within six months to a
year, the trending information generated by a new program
provides the basis for accurate and timely decisions to be made
regarding most critical equipment. This has resulted in
improved maintenance effectiveness to the extent that properly
organized and implemented programs are highly cost-effec-
tive.
This paper describes how a maintenance department can use
the results of predictive vibration analysis to schedule mainte-
nance tasks, improve maintenance inventories, and avoid
unnecessary downtime. Case histories are presented to illus-
trate the critical investment-versus-payback benefit of such
integrated programs.
THE BASIS FOR QUALITY INFORMATION
Quality information is based on three factors: 1) understand-
ing vibration properties, 2) selecting the correct instrumenta-
tion, and 3) program methodology. Each of these factors is
defined in the following paragraphs.
Four vibration properties are crucial to understanding and
resolving machinery problems. These include
RENWICK AND BABSON: VIBRATION ANALYSIS
* amplitude, which indicates the level of severity of the
measured condition;
* frequency, which indicates the repetition rate of the
contributing source or sources of the measured condition;
* phase, which presents the timing relationship between
two signals contributing to the measured condition;
* modulation, the process by which the response amplitude
at some frequency is varied by a lower frequency
excitation response. For example, a high-frequency
response due to resonance would be varied by a ball or
race fault repetition rate. This property also encompasses
the process of envelope detection or demodulation, which
is the ability to decode a modulating wave from a
modulated carrier.
In terms of predictive vibration analysis, modulation is the key
property of interest.
The instrumentation used to measure vibration can vary
widely in both capability and price. The selected instrumenta-
tion should permit the measurement of the four vibration
properties described, since determining a problem's root cause
and its appropriate remedy are the prime objectives of a
successful predictive maintenance program. Table I presents
three common categories of vibration instrumentation and
their respective capabilities. The instrument types have been
categorized according to three levels. Level I represents the
most basic and inexpensive type of instrumentation, Level II
an intermediate type in both capability and cost, and Level III
the most advanced and more expensive type. In planning a
predictive maintenance program, one or more instruments
must be selected which are best suited to both staff capabilities
and program objectives. There can be no substitute for
accurate data at the appropriate time.
Finally, a successfully executed predictive maintenance
program should include the following ingredients in the
program methodolgy:
* dedicated management support,
* planned and organized predictive vibration methods,
* instrumentation with diagnostic capability,
* skilled instrument operators,
* faithful and repeatable surveillance routines,
* reliable and retrievable data records,
* execution and follow-up of recommended maintenance
actions.
The end result of a combination of these factors will be early
detection of impending problems. Such early detection allows
for effective repair scheduling, spare parts control, and man-
hour planning. However, the accuracy of these results are
directly related to the methodology of acquiring appropriate
and useful data. This method must be a reliable proven
technique. One approach to developing a successful data
acquisition method is described in the following section.
THE METHOD FOR QUALITY INFORMATION
Early detection of machinery incipient failures is essential to
the success of a predictive maintenance program. The earlier
the detection, the more effectively a maintenance department
325
can control downtime losses. To evaluate the acceptability of a
measured vibration amplitude signal, charts such as Fig. 1 are
generally used as a guideline until experience has produced
confident bounds for each machine.
The three common measuring units of vibration are shown
in this figure, namely displacement (in peak-to-peak), velocity
(in/s peak), and acceleration (g peak). For a sinusoidal
motion, the relationship of these measurements can be
described as follows:
displacement peak = do sin 2irft = in peak
velocity peak = do2irf cos 2irft = in/s peak
acceleration peak = - do(27rf)2 sin 2wft = g peak
where
do peak displacement,
f frequency, Hz (cycles/s),
t period, s.
Fig. 1 illustrates that for a constant velocity (i.e., 0.1 in/s), the
value of displacement is inversely proportional to the change
in frequency, while the value of acceleration varies in direct
proportion to the change in frequency. Therefore, when
structural vibrations are observed by the measurement of
acceleration, it is possible to take advantage of the relationship
that for a fixed value of acceleration, displacement will vary as
the inverse square of the frequency. Fig. 2 illustrates this
point. An amplitude of 1 g is observed at a frequency of 30
kHz by a displacement of 2.17 x 10-8 in. However, this same
motion would need to be increased 10 000 times to produce
the same 1-g force at a frequency of 300 Hz. By extending
vibration sensing to the ultrasonic frequency range (20-100
kHz) and using high-frequency response accelerometers, a
new dimension is added to structural vibration analysis. For
example, sliding or impacting forces produced by gears,
rolling element bearings, or seal rubs impart broad-band noise
to a machine structure. These excitations usually induce
resonances within the machine structure and its components.
Depending on the level of the driving force, the displacement
level of these resonances may be very small and difficult to
discern. However, by using the relationship described in Fig.
2, together with a signal conditioning technique known as
vibration envelope detection, the component source responsi-
ble for causing the excitation signal can now be detected and
observed at a much earlier stage. Fig. 3(a) shows a typical
channel of a signal conditioning circuit which can be used to
perform envelope detection and input either to a simple storage
device (e.g., tape recorder) or directly to a more sophisticated
device (e.g., real-time analyzer). When subjected to frequency
spectrum analysis, the demodulated output signal of this
device contains the low-frequency repetition rate of the fault
inducing mechanism. This demodulated output signal ampli-
tude can now be easily recognized because the normal
spectrum contribution of low-frequency machine data and
noise has been previously rejected by the high-pass filter.
When obtaining data, the operator now has a greater sensitiv-
ity to incipient fault detection. Advanced screening of incipient
faults is also available to the operator by first utilizing the
326 IEEF TRANSACTIONS ON INDLUSTRY APPLICATIONS. VOL. IA-21, NO. 2 .. MARCH:APRIL. 1985

TABLE I
VIBRATION INSTRUMENTATION CAPABILITIES BY CLASSIFICATION

Level1 I Level II Lev-el IIl

Basic Meters Genera 1 -Purpose Advanced Signal
Anialyzers Analyzers
($1 ,000 - 2.00, ( $2',500 - 7,500) ($7,5(00 - 2',5,000)

Power Requirement
- ac
- dc F F i
- ac/dc rechargeable F

' I F
i X
Measurement F
- Amplitude rms X I X
- Amplitude peak
- Frequiency
F .e II FX
- Phase angle F
- lHigh frequency

Frequency
- Fixed barndwidth
- Tunable broad/narrow F
handwidth
-
Selectable bandwidth - _ x

Display
- Analog meter x
- Digital LCD X X
- CRT display screen X

Diagnostics
- Multiple channel input I X
- Storage/memory _ ~~~~~~~Dslcement in. xPea to Peak) D] - Veluct X
- Selectable sample rate F
- Math functions 1/
- Peripheral interfaces X

Opt ions
- Progranmmable filters .
- Remote control X
- Computer interactive x

Displacenient (in. Peak to Peak) D = Velocil

-rrx Hz

-,$---, $

tL)
0-
a)
C-

xx

0 G

°0/
0/
I_ .

10 100 1000 10,000 100,000

Frequency (cycles/s ( Hz

Fig. 1. Severity of bearing case vibrations: general industrial machinery.

RENWICK AND BABSON: VIBRATION ANALYSIS 327

-)

E
w

'5
a)
__ _ _ _ _ _I_ _ _ _ _ _ _ _ _ _ _ _I
-
2.17 x 10-a
CL

300 30,000
Frequency (Hz)

D = 19.56 (G/f2)
where: D = Displacement in Peak to Peak
G = Acceleration in g Units
f = Frequency in Hz (cycles/s
For a Constant Acceleration of 1 g Peak Force:
* Resulting Motion at 300 Hz
Displacement = 19.56 (1.0/(300]2) = 2.17 x 10-4 in.
* Resulting Motion at 30 kHz
Displacement = 19.56 (1.0/(30,000]2) = 2.17 x 10-8 in.
Fig. 2. Incipient detection using high-frequency analysis: relationship of displacement and acceleration.

alUI sequence established for bimonthly surveillance. The data

Raw Data were taken at each data point and screened for overall
Output amplitude that exceeded a level of 0.20 in/s peak. As shown,
able the motor shaft speed is 200 r/min (3.33 Hz), and the pinion
1, 10
Demodulated gear has 23 teeth, providing a fundamental gear mesh
Output frequency of 76.6 Hz. Based on the 270 teeth on the ring gear,
the speed of the finish mill is 17.0 r/min (0.284 Hz.) These
frequencies were the prime candidates for contributing vibra-
(a)
tion signals to the machine system. The severity (time-to-
Raw Data
Input Integrator
investigate) level of 0.2 in/s peak was the overall amplitude
threshold setting chosen for this machine (see Fig. 1).
(Unity Gain @ 61.4 Hz) Velocity Acceptable velocity severity levels for certain machines, such
Demodulated
Off Peak
Detector
- _ To Meter as hammer or ball mills where impacting is experienced, can
Data Input be raised with confident experience from 0.1 to 0.2 in/s peak.
Acceleration
The first ten months of monitoring (with the same operating
(b)
load) showed that each data point amplitude remained below
Fig. 3. Signal conditioning circuitry. (a) Typical channel
circuitry. (b) Optical mete the threshold value. During the sixth survey (12 months), a
value of 0.26 in/s peak was recorded at pedestal bearing
meter or peak detector portion of this circuit (F'ig. 3(b)). Each location D in the axial plane of reference. This amplitude
data point can be screened quickly to determii ne the need for condition is an indication of thrusting and/or shaft misalign-
additional analysis. ment. A tape recording was obtained at this location, and the
frequency was analyzed to determine the contributing source.
THE RESULTS OF QUALITY INFORI M4ATION Upon inspection of the frequency spectrum (Fig. 5(a)), the
As discussed earlier, combining discrete friequency vibra- major contributor was noted to be at 76.7 Hz, which is the
tion data with the demodulated signal-conditio ning technique fundamental pinion gear mesh frequency. Recommendations
provides early knowledge of developing maci hine problems. were made by Shaker Research Corporation (SRC) to continue
Using this method to diagnose cement pl ant machinery, operation and obtain data every two months. When the ninth
problems has saved hundreds of thousands of clollars over the survey data were obtained (18 months), several locations,
past several years. Many companies have sueccessfully used namely A, C, and D, showed higher-than-threshold ampli-
vibration analysis to solve rotating equipmerit problems in tudes, with the third harmonic (230 Hz) of pinion gear mesh
cement plants, and several representative ca se studies are predominating in each spectrum. A closer look at these
presented below. signatures (Fig. 5(b)) showed that sidebands of 3.3 Hz (the
pinion shaft speed) had also developed. Signature character of
Case Study 1: Finish Mill this type suggests eccentric gear motion caused by pinion shaft
The first case study involved the detectilon of a loose misalignment. Since the pinion shaft coupling was closer to
pedestal bearing on the pinion drive of a finirsh mill. Fig. 4 pedestal bearing C and the data showed the most response at
presents a description of the machine layout ancd the data point pedestal bearing D, a recommendation was made to inspect the
 32 8 IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. IA-21, NO. 2., MARCH/APRIL 1985

COMPANY NAME: Cement America MACHINE NAME: Finish Mill

ADDRESS: Production Avenue PLANT LOCATION: Qualityville, U.S.A.
_Qualityville, U.S.A.

N = Horizontal V = Vertical A - Axial 801136-2

Fig. 4. Finish mill machinery information sheet.

would have reduced the plant production rate by 30 percent. In

Twelve Months
2
a
0.3 I addition, failure of the pinion gear would have resulted in
a. 76.6 Hz Xl Pinion Gear Mesh several days of downtime that would have cost approximately
0

e
1
0.2
$88 000, as well as $34 000 for a replacement gear. This case
'a study illustrates that, while overall amplitude can detect a
.5-a
0
Motor X problem, signature analysis revealed the cause, allowed
Shaft X
> 0.1 alleviation of rapid deterioration, and permitted trending of
a this condition until regularly scheduled maintenance could be
a
performed.
0 ~50()O
Frequency (Hz)
Case Study 2: Cooler Vent Fan
(a)
The second case study involves a plant startup monitoring
Y2 03 Eighteen Months |- 230 Hz X3 Pinion Gear Mesh program where the shearing of coupling bolts on a direct-drive
a.
tL
cooler vent fan motor shaft was beyond the fan manufacturer's
ax
-~
0
02 ability to solve. In this case, the threshold level for overall
'a amplitude was set at 0.10 in/s. The shaft speed was variable
Shaftor xiSidebad Generation between 400 and 1100 r/min (6.67 and 18.3 Hz) as a function
>
a) 0.1 of load required. Vibration monitoring of the data locations
(see Fig. 6) showed no unacceptable amplitude level.
3

E
0
L 1 . i Ii
500
The coupling bolts were sheared on two successive occa-
Frequency (Hz) sions within one month after initial startup. Misalignment of
(b) the motor or fan shaft should have shown a high axial
Fig. 5. Finish mill loose pedestal bearing signature. amplitude response at bearing locations A and/or D of one,
two, and/or three times the fundamental shaft speed. The
pedestal support mounting. This investigation revealed two of presence of a critical speed' should have sent the amplitude
the four mounting bolts were loose and some disintegration meter many times above the threshold setting, but neither of
and cracking of the pedestal foundation were noted. When the these conditions was observed. Several vibration sensors were
loose pedestal bolts were tightened, the response levels were then placed on the motor and fan bearings. A torsiograph,
reduced by 20 percent. This allowed the machine to operate which measures shaft system torsional vibration response, was
under normal load (with weekly surveillance) for an additional also installed on the outboard fan shaft to observe continuous
three months until a planned shutdown permitted the necessary
corrective action. A premature shutdown of this one mill The shaft speed at which a system's natural frequency is excited.
RENWICK AND BABSON: VIBRATION ANALYSIS 329
COMPANY NAME: American Cement Ltd. MACHINE NAME: Cooler Vent Fan
ADDRESS: Production Avenue PLANT LOCATION: Qualityville, U.S.A.
Qualityville, U.S.A.

DRIVER UNIT DRIVEN UNIT

MFG. General Electric MFG. Buffalo Fan
MODEL MODEL
TYPE Direct Drive TYPE Centrifugal
GEAR RATIO GEAR RATIO
HP 1000 hp CAPACITY
MISC. 1155 rpm MISC. -_-
TYPE OF TRANSDUCER TYPE OF TRANSDUCER
OIEPLACECENT VELOCITY ACCELER- DISPLACEMENT VLOCITY ACCELER.
SEARING PROSE PROSE OMETER SEARING PROS PlOSE OME
A 0 00 W0 P 00%E I 0 00 0 00 00 0
H V A H V A H V A H V A H V A H VA
BA
HV
0 In Do
H V A
0%gkgM
H V A
J o OOOOO O
H V A H V A H VA
H ;' )l
H '
V 5A
C D3 O O P1 3 3
HDO H00V 0
K 0
H00V 0
D V A H V A V A A A
D Pt 18 Pt
O aCo131 o
0 L o3 o3 o3 o D O O O O
H V A H V A H V A H V A H V A H V A
0 0 0l 0 03 0 0 0 0 TRANSDUCER
TYPE
FREOUENCY _ TOTAL NO.
H V A H V A H V A RANGES SIGNALS
0
-A |(DISP.
F
G
H" V- A-,
u u u u
H V A
"HH A-VV ",AA ,HH "V oIVEL
u u u u
V Al
10 kHz
2 kHz
i 3
12
jl-tj.m.tt t" -I -t tti.-
H H V A
O O O O O O § ACC. 10 kHz 6
H A N V A
H = Horizontal V = VerliclE A = Axisl e1
80116
Fig. 6. Cooler vent fan machinery information sheet.

response under all operating loads (see Fig. 7(a)). The analog
output signal of each sensor was then observed as a function of
time on the CRT of a fast fourier transform (FFT) real-time
spectrum analyzer. The analyzer sampling was set at a high
rate to capture any transient signals. As shown on Fig. 7(b),
large amplitude spikes were noted from the signal output of the
torsiograph sensor each time a speed increase change was >
required from the motor. A high-speed chart recorder observ-
ing motor amperes also reported excessive swings at the time
of motor speed change. These data recordings gave evidence
that the motor controller circuit was demanding instantaneous
torque changes from the motor upon load demand. The high
inertia fan load was too much for the motor to respond to that
quickly. Undue torque was then transmitted to the coupling s
bolts (the weakest shaft link) and sheared them. The controller (a)
was properly adusted to dampen and no further problems have 1.4
been experienced over three years of operation. Three other
fan drives which had not yet been put in service were also
found to require the same controller adjustment. This particu-
lar experience showed that basic or general-purpose vibration
monitors could not detect the problem. However, the problem
was detected and addressed by the use of advanced techniques
and real-time spectrum analysis.
Case Study 3: Gear Reducer
The final case study involved the detection of a bearing fault
in a large triple-reduction right-angle gear reducer whose shaft
operated at 1200 r/min (20 Hz). Vibration data were taken and
reviewed at bimonthly intervals for unacceptable overall
amplitude values. Fig. 8 illustrates the gear case observation S

(b)
points. Note that data point A is the high-speed pinion shaft Fig. 7. (a) Torsional time trace. (b) Time trace: fan pedestal outboard
outboard bearing. bearing torsional response.
330 IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. IA-21. NO. 2.. MARCH/APRIL 1985

Fig. 8. Triple-reduction right-angle gear reducer.

The high-speed pinion was a spiral bevel gear with 29 teeth

and a fundamental gear mesh frequency of 580 Hz. The pinion
shaft was supported by double-roller rolling-element bearings 0.03
l _ ~~~~~~~~0.03
g Pk
on each side of this gear. During the first 12 months of _~~~~~* 580 Hz
bimonthly observation, the maximum amplitude at this loca- a- 0.022 > _
Xi Pinion Gear
~~~~~~~~Mesh
Frequency
tion was 0.30 g peak (0.032 in/s peak) (see Fig. 9(a)). Over
the next six months, this amplitude value trended to 3.0 g peak c
-0.01
(0.318 in/s peak), the suggested shutdown limit (see Fig. 1).
This signal was recorded and reviewed. The predominant
component response was the fundemental pinion mesh fre- Frequency (Hz)
1 kHz
quency of 580 Hz (Fig. 9(b)). However, most significant were (a)
the sidebands (20 Hz) generated on each side of this
component excitation. The pinion mesh frequency was being 0.30 _---- 580 Hz
Xi Pinion Gear
Mesh Frequency
modulated by the pinion bevel gear shaft speed of 20.0 Hz, to
0. 20 Hz
S'debands
which suggested two conditions. First, the pinion gear was o
a)
0.20
1(2 20 Hz
moving with an eccentric motion, and second, but more Motor
Shaft
Intermediate
Pinion Mesh
Sidebands

important, the driving motion was the pinion gear shaft at its 0.10
rate of speed (20.0 Hz). This meant that the problem source
was along the pinion shaft. Demodulating the time trace signal 1 kHz
Frequency (Hz)
(Fig. 9(c)) showed that a bearing fault (outer race) repetition
rate was present and pronounced. Disassembly of the reducer (b)
case showed that the inboard pinion shaft bearing was loose -- -1 Shaft Revolution
and had developed outer race faults. The pinion bevel gear was
inspected and found to be developing an abnormal wear
pattern at the upper portion and to one side of each tooth. The
technique of high-frequency signature analysis once again
proved to be timely and cost-effective. The cost of this mill's
> 0

H-
Period of
7--r - -r Period
Resonant
ot

downtime was $2000/h, while the cost of a replacement Ball Pass

Frequency
Time (s ) Frequency

reducer was $200 000 with a 14-month delivery time. (c)

THE BENEFITS OF QUALITY INFORMATION Fig. 9. Gear reducer bearing problem. (a) Frequency signature at 12
months. (b) Frequency signature at 18 months. (c) Time trace signal at
While few will argue against the value of quality informa- 18 months.
tion received on a timely basis, different opinions exist
regarding what costs should be incurred to obtain this
information. Fig. 10 illustrates these arguments and how they
affect the cost of reliability. The goal of a maintenance budget
RENWICK AND BABSON: VIBRATION ANALYSIS 331

a shutdown criterion. Bearing and gear problems require

discrete detection.
Case History 3: After 70 percent degradation, the time
period for this event is still much too fast for the Level I
instrument to capture and report -transient signals. This
instrument would only report that a gross deficiency exists and
failure is imminent.
Level II: General-Purpose Analyzers
.*_
*-*
_
-
/
< ~~~~~~~~~Preventive
~~~~~~~~
Case History 1: After approximately 50-percent degrada-
tion, the amplitude change would be observed and each
Maintenance

contributing frequency component -tuned to and presented for

~~~~~~
-
_ 1
tCost of Lost
~~~Production _ review and documentation.
Case History 2: After approximately 50-percent degrada-
Low w
trHigh tion, the amplitude change would be observed and each
Reliability
contributing frequency component tuned to and presented for
(Productivity and Product Quality) review and documentation.
Case History 3: After approximately 70-percent degrada-
Fig. 10. Quality information versus cost of reliability.
tion, the Level II instrument, although capable of reporting
frequency contribution, is not capable of reporting transient.
is to remain at the bottom of the solid line curve to maintain the
highest reliability with the lowest combined costs. It should be
Level III: Advanced Real- Time Analyzers
stressed that it is risky to justify a predictive maintenance
Case History 1: After approximately ten-percent degrada-
program on the chance that one spectacular save will pay for
tion, the immediate changes in gear mesh signature character
the program. While this gamble may pay off, the opportunity
could be captured with high-frequency sensing and displayed
for it may not arise during the program's trial period, possibly
for FFT real-time spectrum analysis.
because several saves were made early on and not counted. It
Case History 2: After approximately ten-percent degrada-
would then be difficult to continue to justify the program.
tion, the immediate changes in bearing and gear signatures
As the benefits from more efficient planning due to better
could be detected by demodulation and easily recognized by
knowledge of equipment result in measurable savings, this
comparative analysis displays available in FFT analyzers.
information should be used to justify the program. Spectacular
Case History 3: After approximately ten-percent degrada-
saves should be regarded as a bonus. A review of maintenance
tion, the analog (time domain signal) can be used in
records over a two- to three-year period will identify expendi-
conjunction with a signature (frequency domain signal) to
tures, such as overtime premiums, product loss, and unneces-
recognize transient spikes introduced to the system being
sary shutdowns, that could have been avoided if predictive
monitored. Electrical and mechanical forcing functions can be
maintenance was in place. Put a realistic value on these differentiated through the use of special features, such as zoom
expenditures. Then to be conservative, use 70-80 percent of
(high resolution), with FFT instrumentation to define the
this value to account for saves which may have been missed
problem's root cause.
early in the program. A standard number now exists to Thus it can be seen that Level III instrumentation will not
measure program benefits and what could be invested in a
only produce longer lead times but will usually identify a
program to circumvent these problems.
problem's root cause and permit timely, effective mainte-
In the case studies reviewed, complicated problems were
nance. Level I instrumentation- is certainly better than none at
addressed which required both troubleshooting skills and all but will give less lead time and often requires the additional
complex data. These case studies are now reviewed in relation
expense of using an expert to troubleshoot a problem for which
to the three instrumentation classifications presented on Table
the cause cannot be identified. Starting on a limited budget
I and to the problems each type of instrument would have
with Level I instrumentation and then progressing as experi-
detected.
ence is gained has merits. A reasonable level of initial
investment would be 0.5 percent of the total maintenance
Level I: Basic Meters budget. The continuing costs of operating a program can be
quite low if done with existing personnel. A program tvhich
Case History 1: After approximately 50 percent degrada-
incorporates the strong basis in vibration methods, instrumen-
tion, an overall amplitude level change would be reported to
tation, and a program methodology discussed in this paper
the operator. However, no diagnostic capability would be should see profitable results within a 12-18-month period,
available to present the frequency of contributing forcing i.e., a $3-5 savings for each dollar spent. Most of SRC's
functions. cement plant customers using Level III instrumentation have
Case History 2: After approximately 50-percent degrada- even saved the value of the program in the baseline survey
tion, an overall amplitude value would be useless other than as used to establish the current machinery condition. However,
332 IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. IA-21, NO. 2., MARCH/APRIL 1985
the final judgment as to the extent of the investment rests with
the plant's maintenance group.
John T. Renwick studied mechanical engineering
at Union College and received the associate's
degree in electrical engineering from Hudson Val-
ley Community College, Troy, NY.
He has over 20 years of experience, during which
time hehas developed particular competence in
automated data acquisition and computerized digital
signal analysis as they relate to machinery diagnos-
tics for the predictive maintenance and equipment
repair market. He was Manager of Periodic Man-
agement Services for Shaker Research Corporation,
Latham, NY, a wholly owned subsidiary of Mechanical Technology Inc. He
was repsonsible for the planning and development of industrial monitoring and
diagnostic programs designed to increase the availability of plant rotating
machinery. He is now with Vibration Analysis Inc., Coral Springs, FL.
Paul E. Babson received the B.S.M.E. degree
from Rensselaer Polytechnic Institute, Troy, NY.
He is Director of Marketing for the Shaker
Research Corporation (SRC), a wholly owned
subsidiary of Mechanical Technology Inc. (MTI) of
Latham, NY. SRC provides technical support serv-
ices to industry consisting of machinery trouble-
shooting and computerized machinery diagnostic
systems for automated vibration analysis.