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Divisions 6

DoctorKnow® Application Paper

Title: PHASE MEASUREMENTS-Fundamental Uses For Single and Cross
Channel Phase
Source/Author:Ken Jackson
Product: General
Technology: Vibration
Classification:

PHASE MEASUREMENTS
Fundamental Uses For Single and Cross Channel Phase

Written By:
Kenneth E. Jackson III
CSI Training Manager

BIOGRAPHY

Mr. Jackson has been involved in the vibration and maintenance of large machinery for the
past twelve years. As the manager of CSI Training, Ken is responsible for the training
activity in Knoxville, Houston, Brussels, and CSl's newly formed Authorized Training
Centers (ATC's). Additional responsibilities include teaching classes such as Single and
MultiChannel vibration analysis, Turbine Theory, Principles an Applications, Power
Generation, and Control Console Troubleshooting for both relay and PLC type control
Systems.

Ken's vibration experience includes over twelve years of advanced vibration analysis and
system diagnostics including; multi-channel analysis, force/response testing, coherence
testing, orbit analysis, spectral and waveform. Ken holds a BS in Mechanical Engineering
from San Diego State University, and is Vibration Institute Certified for Specialist levels I
and II.

ABSTRACT

The purpose of this paper is to define phase and identify the different methods of acquiring
phase data utilizing both single and multi-channel analyzers. Where phase measurements
are a tool to be used in the analysis process, the overall focus of this paper is to discuss
some of the applications where phase may be utilized for the determination of a machine
defect.

INTRODUCTION

Special measurement technique is the only way to describe the function of phase and it
use in determining machinery faults. Phase measurements may be acquired in different
ways, and therefore we will cover some of those methods for acquisition, as they related to
specific applications. We will discuss the function of phase as it is related to the following;

Synchronous Phase - The monitoring of phase with the aid of a band pass filter, for
component frequencies only related to a rotational component. (i.e. 1, 2, and 3xRPM etc.)

Phase Spot Checks - The comparison of phase data for the determination of faults and/or
the understanding of direction of motion as well as the forcing function.

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Bode & Nyquist Plots - Determining the phase condition of a rotating shaft during the
startup or coastdown specifically for the purpose of determining resonance conditions
(critical frequencies).

Cross Channel Phase - The by product of the cross spectrum and useful when
determining resonance conditions along with operating frequency relationship without the
aid of Tachometer pulse.

WHAT IS PHASE?

The question that one must ask is; "what is Phase?" Phase is a relationship. This
relationship is simply the difference in time between two events.

Figure 1 Phase Calculation Illustration

Phase is one of the most important vibration analysis tools a analyst can have at his or her
disposal. The analyst uses phase when trying to balance an unbalanced rotor to locate the
heavy spot. Phase is also a useful tool to determine types of unbalance, misalignment,
looseness, soft foot, bearing misalignment, resonance and other machinery faults.

The illustration shown above provides some insight for understanding phase and the
meaning that it has in industry with respect to machinery diagnostics.

The signal labeled "T" is a tachometer reference pulse. This may be generated with a
strobe light, infrared or photo tach pulse. The signal label delta X is the vibration signal
representing an unbalanced rotor condition (1xRPM). When calculating phase using the
single channel instrumentation available today, one has invoked a two channel function.

Phase as stated earlier is the relationship between two signals. This relationship is based
on the differential time between the two signals.

The difference is considered the t. This time is calculated from the start of the tachometer
pulse (the reference signal) and the time required to see the unbalanced (the comparison

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signal) condition following the reference pulse. With this time, the ability to determine the
relationship between the two signals becomes much easier based on the following
calculation.

With the ability to draw this relationship in time, the analysts' proficiency in analyzing
specific machinery faults becomes enhanced.

Phase measurements are very important when diagnosing and correcting machine
unbalance. However, other machine faults such as misalignment and soft foot can show up
at 1x RPM similar to unbalance. Therefore, understanding the phase relationships of
unbalance, misalignment and looseness and other machine faults can provide further
assistance in the prevention of an improper fault diagnosis.

SPECIFIC FAULT TYPES

The following machinery faults are the most common conditions that may be differentiated
with the aid of phase.

Unbalance - Static unbalance will show a zero degree phase shift across the rotor radial to
radial or horizontal to horizontal, a 90° (20°) phase shift from vertical to horizontal at the
same bearing location. Dynamic unbalance shows a phase shift across the rotor radial to
radial or horizontal to horizontal that is related to the heavy spots on each end of the rotor.
If the heavy spots are 180° out of phase on each end, then the phase measurements will
also be 180° out of phase.

Misalignment - Angular misalignment will typically show a 180° (30°) phase shift across
the coupling in the axial direction. Parallel misalignment will tend to show a 180°( 30°)
phase shift across the coupling in a radial direction. Bearing misalignment (cocked bearing)
will show a 180°(± 30°) phase shift from one side of the bearing to the other or from the top
of the bearing to the bottom.

Looseness and Soft Foot - Phase reading with looseness will be erratic from point to
point around the machine train. A sot or loose mounting foot usually shows a phase shift
from the foot itself to the foundation. Often this shift will be greater than 90°. Also a sot foot
would show a phase difference from the other machine feet.

Resonance - The phase shifts 180° from the frequencies below resonance to the
frequencies above resonance. A 90° phase shift will be present right at the resonant
frequency.

DIFFERENT PHASE MEASUREMENTS

There are numerous methods of determining phase relationship between two components
and/or signals. Remember there must be a common denominator "Time". If there is a
common time base like that illustrated in figure 3 the relationships may be drawn.

Waveform Comparisons

As we see below the two signals representing the outputs of X and Y displacement probes
appear to be approximately 160 degrees out of phase. This is a significant difference due
to the fact the probes are mounted 90 degrees apart.

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Utilizing a single channel instrument, phase is measured by using the once per revolution
pulse as a reference point. However, the necessity for a once per revolution pulse is no
longer required with the presence of a multi-channel FFT Analyzer.

TWO CHANNEL PHASE

Expanding on the definition previously stated, cross channel phase measurements only
simplifies, and expedites phase data acquisition. Of all cross channel measurements, cross
channel phase is the most sensitive vibration parameter.

Some multi-channel FFT analyzers require a specific input channel. In the event the
channel is setup incorrectly, cable changes are required. The alternative to this problem is
taking the orientation into account and adding 180°. Others provide the ability to determine
which input signal can be the reference without changing cable connections.

The following are some basic considerations that must be taken into account when
acquiring multi-channel phase data:

· An accelerometer is the only 'true phase" transducer

· The multi-channel FFT analyzers have no internal phase shift between channels

Depending on the machine fault present, a machine's structure will either be moving as
one unit, in phase, or not as one unit, out of phase.

When analyzing machinery conditions, there typically is a suspected problem. With this
suspected problem, the necessity to acquire phase data is present yet in many cases
virtually impossible to gather with a single channel instrument.

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With the aid of a multi-channel analyzer the ability to acquire phase data becomes less
difficult.

The phase spectrum in figure 5 at the top of the illustration demonstrates how a phase
spectrum can be utilized.

The phase spectrum shows the difference in phase between channels "X" and "Y".
Channel "X" served as the references for this measurement, therefore, the phase
calculated was the difference from channel "X" to channel "Y"

Also utilized when determining resonant frequencies during two channel impact test or
modal studies.

The data in figure 6, illustrates the use of cross channel phase when employed in
resonance detection. The phase relationship was drawn between a instrumented force
hammer, and a response transducer (accelerometer). The lower plot is the averaged
response spectrum, while the data above is the phase spectrum from channel "X" the
Hammer Output and channel "Y" the Response Accelerometer.

The data clearly displays the phase shift of the resonant frequency.

OTHER PHASE MEASUREMENTS

Monitoring the amplitude and phase response during a startup or coast down is a method
of using peak and phase measurements to determine resonances.
The analyzer should be placed in monitor peak and phase mode at the turning speed
harmonic of interest. The machine should then be shut off. Take care to ensure that the
peak and phase data is sampled fast enough to capture meaningful data.

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When you monitor synchronous phase during either startup or coastdown, you can
categorize the data into three areas of interest peak vs. RPM, phase vs. RPM, and Nyquist
data.

The linear plot below shown is referred to as a Bode Plot shows pieces of information. The
lower plot displays the peak amplitude values with respect to the change in machine RPM.
The plot above displays the phase change with respect to the same changes in machine
RPM.

The phase reading taken from a monitored machine should change by approximately
180as it runs up to speed, passes through the resonance range(s) and moves into the free
space region. At the resonant frequency, the phase reading is always unstable. Phase
should, however, differ by roughly 90° from that measured in the free space region.

The same holds true when the machine is turning too slow to experience vibration
amplification due to resonance.

Bode plots (peak or phase vs. RPM) yield important information about resonance. The
presence of runout, however, or a bow in the shaft, can significantly alter the appearance
of the plots. Nyquist plots, on the other hand, remain unaffected by runout and bowed
shafts. Always use Nyquist plots to confirm any conclusion based on Bode Plots.

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The illustration above shows the important features of the Nyquist plot. Note that any loops
in the plot are evidence of the other resonant frequencies. Note the similarities between the
plot at left and the illustration on the previous page. Pay close attention to the following
points:

· Speed reference (cursor)

· Location of residual unbalance

· Location of resonance speed from the residual unbalance

The actual data shown above illustrates

the same information addressed in the Bode plot discussion.

The resonant peak in the Bode plot was at 1644 RPM, additionally we could see the phase
shift was approximately 90° (or in the center if the overall phase shift).

In the plot displayed at left, the 1644 RPM is 180° (opposite) from the gap. Each side of the
gap also provides information for determining the resonance amplification range.

EXAMPLE USE OF PHASE DATA

The Illustration above displays the functionality of phase in diagnosing machinery faults
such as soft foot, and resonance conditions.

History- The High Pressure Centrifugal pump began having problems with vibration and
the machine plant in which it operated had no vibration monitoring equipment. Company
personnel called CSI to troubleshoot the problem and recommend a fix for the identified
problem if possible.

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Upon arrival to the facility, the brace shown in figure 11, was put in place in an attempt to
strengthen the structure in order to keep the weld location shown from cracking.

Initial Plan of Attack- With the knowledge of the cracks that were occurring, the initial
thought was a resonance condition since cracks are typically a result of high structural
stresses common caused by resonances. The question we then had to ask was; "what's
causing the resonance?".

Initial Data Acquired - Data was acquired in the radial positions of the Motor Inboard
(coupling). This initial data provides the initial forcing functions generated from the motor,
provides some relationships, and a starting point from which we can build a fundamental
understanding of the machines condition.

The previous data shows a significant difference in amplitude in the two respective plains.

The spectrum of this data differentiated to velocity shows the majority of the energy at
1xRPM of the motor speed. The first question is; "Why?" The second question is; "how is
this causing the flange weld to crack?"

There has yet to be a tie in as to how this significant 1XRPM peak is causing the cracks.
As stated earlier, cracks and the such like are indicative of resonances. With this in mind,
two channel impact data was gathered to determine what frequencies are potential
problems.

The impact data shown in figure 14, was gathered in the vertical plain, located at the point
where the structural cracks were occurring.

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Clearly there are two resonance conditions as shown by the increases in amplitude with
the corresponding phase shifts in the phase spectrum in figure 14.

The data shown if figure 15, was gathered in the horizontal plain at the defect location.

Again there is a resonances as identified through the increase amplitude accompanied with
a significant phase shift at the same frequency.

The most important part of the impact data collected in the horizontal plain is the frequency
at which the resonance is located. The resonance peak is at 59.5 Hz. This is the same
frequency the motor was operating at under load when the initial data was gathered. (see
figure 12).

According to the operator, there has been no operational changes to the pump assembly.
There has been no maintenance performed on the motor pump combination either. The
question then becomes; What internal changes have occurred causing the change in the
machines operation. The relationship between motor speed (59.5 Hz) and the horizontal
resonant frequency also at (59.5 Hz) provides the clue to the puzzle.

The data shown above in figure 16 was gather across the coupling the axial direction. The
phase difference at the operating frequency is significant in the solution to the problem.

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The Diagnosis- There is a great amount of energy being transmitted across the coupling
in the axial direction. The coupling is either badly out of alignment, or the coupling has
locked up. This is indicated by the phase shift in the forcing function across the coupling.

Recommendation - The data suggest that the machine be shutdown and the coupling
inspected for the following.

· Insure the coupling has been properly lubricated.

· Check the alignment, and ensure the coupling is aligned with a precision instrument.

· Inspect the overall condition of the coupling for excessive were and possible future failure.

All of the above recommendations should be conducted with a high priority to ensure the
condition does not continue.

Problem Summary- During the initial stage of the recommendation (inspect the coupling)
the coupling when opened could not be separated without the use of a mini sledge
hammer (The coupling was locked). Once separated the rusted coupling (Lack of
Lubrication) had deteriorated so severely that portions of the coupling could not be
accounted for.

The data in figure 17 was taken with the motor running un-coupled.

The change in the spectral character is a result of the actual motor speed and the electrical
field speed being so close that there is a beat frequency that has developed.

SUMMARY

Through the course of this paper phase has been covered in various manners for the
purpose of showing the functionality of both single and cross channel phase
measurements. Detailed illustrations and data assisted in defining the term phase and
provided applications where in it may be used for diagnostics and corrective maintenance
activities such as field balancing. Phase in general provides the analyst with additional
insight to the condition of a machines operation, and possible faults.

The differences between single and cross channel phase, although calculated in the same
basic manner, the difference can be severe.
This severe difference in phase is typically a result not having a common time base for the
signal relationships being drawn.

All contents copyright © 1998 - 2006, Computational Systems, Inc.

All Rights Reserved.

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