Vibration Severity & Noise Limit For Diesel Generating Sets

Dr. R. Sharma
&
S. N. Misra

Abstract :Vibration, its effects, analysis and vibration severity levels (as per various standards) are discussed in
this note specially with reference to the Diesel Generating Sets. Further to this the salient provisions of G.S.R.
371(E) dated 17th May 2002 , Environment (Protection) second Amendment Rules, 2002 are also discussed.

1.0 Introduction :Vibration

Abnormal large vibration level of a machine always implies a symptom of bad production in
assembly line viz. mechanical or electrical unbalance, deformation of core or shaft, loose
parts etc. Abnormal vibration will introduce large stress on machine construction itself, or
connected equipment and thus ultimately the service life. Therefore, some vibration limits are
specified in order to avoid MTBF (Mean Time Between Failure).
Before vibration criteria is introduced, some vibration terminology and concepts are
explained following vibrating spring-mass system.
From physical and mathematical derivation we have,
Vibration displacement, x = XSin ωt
dx
Vibration velocity, v= = ωX Cosωt ; and
dt
d 2x
Vibration acceleration, a = 2 = -ω 2 x ;
dt
Where
ω is the rotating angular velocity,
x is the root mean square (r.m.s.) displacement,
X is the peak displacement, peak to peak value ,
T is the period (= 2/t), and
f is the frequency (=1/T) .

1.1 Vibration Severity

Vibration severity defined as a comprehensive and simple characteristic unit for describing
the vibratory state of a machine is used as the basis of classification and, on the basis of
theoretical considerations and practical experience, the root mean square value of vibration
velocity has been chosen as the unit of measurement for indicating vibration severity.
‘Vibration Severity’ is a generic term which designates a value, such as a maximum, average
or other significant numerical value descriptive of a vibration. The vibration severity of a
machine is defined as the maximum of r.m.s. value of the vibration velocity measured at
significant point of a machine such as a bearing, mounting point etc.

1.2 Vibration Analysis

Vibration measurement systems fall into the following categories:

Single Value Methods

Hand Held meters
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SPM Units
Acoustic Emission Units
Vibration Pens
4-20mA sensors

Time Frequency Methods

Hand Held Data-collectors
On line systems

1.2.1 Single Value Measurements

The variety of single value measurements is endless, from the ISO filtered levels mentioned
in ISO 10816 [1] to the ‘magic numbers’ offered by some of the technology vendors;
promising to solve all of your plant condition problems within one simple solution. ISO
10816-3 is summarised as a supporting appendix to this text.

Please note single value methods are either ‘generic’ or ‘specific’. The generic case is where
a value will indicate the presence of ‘a problem’ but cannot categorise the problem into a
specific fault (e.g. Unbalance, looseness, misalignment, cavitation etc.). The specific methods
concentrate on issues such as bearing faults and try to eliminate the influence of ‘other’ faults
through the use of algorithms and electronic design.

The following table outlines the more common types of measurement with comments on
applications and a brief technical description of the method.

Single Value Method Summary

Method Description Applications
ISO Filtered Velocity 2Hz – 1kHz filtered Works as a general condition
Velocity indicator.
SPM Carpet and Peak related to One of the better single value
the demodulation of a bearing indicator methods.
sensor resonance around Some problems on larger
30kHz. bearings and gear units.
Acoustic Emission Distress & dB, Better general indicator than
demodulates a 100kHz ISO velocity, without the ISO
carrier which is sensitive comfort zone.
to stress waves.
Vibration Meters / pens Combine velocity, Look for ISO Velocity,
bearing and acceleration envelope & high frequency
techniques (sometimes acceleration for best
include thermal) performance.
4-20mA sensors Filtered data converted to ISO velocity version
DCS/PLC compatible available, envelope version
signal. still awaited.
Can be used to ‘home in’ on
specific problems by special
order.

Single value vibration methods have two major advantages and only one real disadvantage;
these are low cost, simple interpretation and lack of accuracy respectively. The overall CM
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system implications of single value methods are discussed within the later sections of this
text.

Single value data are easy to trend and interpret as shown by the inset plot below.

1.2.2 Time Frequency Measurements

This type of measurement involves the detection and display of specific components of a time
history sensor output. The use of specific frequency components lends itself to the detection
of faults down to a single mechanical component (e.g. bearing, gear, impeller).

Once again, various methods, techniques and signal conditioning systems are used to detect
specific components of the raw time history data.

1.2.2.1 Displacement (Low Frequency)

Where the measurement of absolute movement is required, measured using LVDT’ s or eddy
current probes. Particularly useful in detecting the relative position of a rotor versus a
structure and in the diagnosis of plain bearing faults through the use of orbit plots.

1.2.2.2 Velocity (Mid Frequency)

The most commonly used method for fault identification, mainly due to the scalar
consistency of the method (i.e. 25mm/s is high almost irrespective of the machine type). Used
to detect signs of mechanical problems in the frequency range 20Hz – 2000Hz. Detection
capabilities cover the following fault conditions.
Unbalance, Misalignment, Looseness, Resonance, Cavitation, Blade problems, Turbulence

1.2.2.3 Acceleration (High Frequency)

Amplitude Demodulation Methods

Used to extract impacts from the standard acceleration spectra through the extraction of the
amplitude-modulated component and the display of the demodulated components within an
auto-spectrum plot.

Impacts are created as a rolling

element collides with a damaged
area.

These impacts show as transients

within the time domain. The
Demodulator extracts these
transients.

Extracted impact frequencies are

then displayed on an envelope
spectrum (shown opposite)
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There are two main types of envelope measurement, namely:

Band Pass Filtered Enveloping

Allows the time history associated with the excitation of a specific frequency band pass
through to the demodulator circuit. This method avoids the possibility of phase cancellation
and is better at isolating the transient activity.

High Pass Filtered Enveloping

Sets a High Pass filter and allows all measured time data above the HP filter pass to the
demodulator, this method is regarded as less effective by vibration practitioners.

General Acceleration

Where rotating machine related frequency components are expected above 2kHz, velocity
measurement is not accurate due to sensor noise levels. Acceleration time frequency analysis
tends to be used for the detection of fault components from: -
Any gear assembly (gearbox, timing gear, gear pump)
Where amplitude demodulation methods are not available (to detect a ‘haystack’
within the high frequency spectra)
High speed screw assemblies.
Turbochargers
Blading problems on turbo-machinery
High frequency resonances
Detection of gear and rub related transients

SUMMARY – Vibration

Combined Vibration Meter – Low Cost and easy to use (look for ISO Vel &
Enveloped acceleration)
Acoustic Emission Meter – Reasonable alternative Combined Vibration Meter (good
for low frequencies)
Time Frequency (Datacollector) – Required for specific and more accurate fault
diagnosis, choose band pass envelope method as bearing assessment technique.

1.3 Conclusion

From the above analysis it may be seen that the vibrations generated by the engine are
complex and contain harmonics of 1.5, 3, 5 or more times the fundamental frequency of the
vibration. The generator will be subjected to this vibration which will result in the generator
being subjected to vibration levels higher than those derived from the generator itself. Thus it
becomes imperative to specify the limit of vibration severity for rotating machineries.
Accordingly, a summary table is appended herewith as Appendix I (Summary of ISO 10816-
3) and Appendix II (Summary of IS:12075-1987).

2.0 Introduction :Noise & Emission

People are becoming more aware of hurt of noise to human beings in recent years and thus
give more demands on noise suppression. To evaluate how "large" a noise is, the acoustic
quantities can be expressed in two types of terms, sound power level and sound pressure
level.
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w
Sound power level, Lw =10 log 10 ( )
w0
where
Lw is the sound power level in decibel (dB)
w is power output from the sound source in watt
w0 is the basic sound output, 10 −12 watt, which is defined from the minimum audible sound
intensity of human ear, 10 −12 watt /m 2 .

P 2 P
Sound pressure level (SPL), L p =10 log 10 ( ) =20 log 10 ( )
P0 P0
where
L p is the sound pressure level in decibel (dB);
P is the effective sound pressure in N/m 2 (Pa). (Physically equivalent to root-mean square
value of sound pressure function of time) ; and
P0 is the basic sound pressure, 2*10 −5 Pa, which is defined from the minimum audible sound
pressure of human ear .
Human ears often have different hearing sense for different frequency components of the
sound with the same loudness. A correction function, A-weighting filter, is introduced in
noise-meter to correct the measured sound level in octave band to simulate human ears’
hearing perception, and the unit is expressed as dBA. The A-weighting function curve and
adjusted values corresponding to center frequencies of octave band are shown as follows:

Centre Adjusted Centre Adjusted Centre Adjusted

Frequency Value (dBA) Frequency Value (dBA) Frequency Value (dBA)
(HZ) (HZ) (HZ)
31.5 -39 250 -9 2000 +1
40 -35 315 -7 2500 +1
50 -30 400 -5 3150 +1
63 -26 500 -3 4000 +1
80 -23 630 -2 5000 +1
100 -19 800 -1 6300 0
125 -16 1000 0 8000 -1
160 -13 1250 +1
200 -11 1600 +1

A-weighting function has large attenuation in low frequency range.

2.1 Provisions made in the Noise Protection Rules

With above backgrounds in mind the Government of India Vide para 94 has prescribed the
noise limit as follows:

2.1.1 Noise Limit for Diesel Generator Sets (upto 1000 KVA) manufactured on or
after the 1st July 2003

2.1.1.1 The maximum permissible sound pressure level for new diesel generator (DG)
sets with rated capacity upto 1000 KVA, manufactured on or after the 1st July, 2003 shall be
75 dB(A) at 1 metre from the enclosure surface.
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2.1.1.2 The diesel generator sets should be provided with integral acoustic enclosure
at the manufacturing stage itself
2.1.1.3 The implementation of noise limit for these diesel generator sets shall be
regulated as given in paragraph 3 below.

2.1.2 Noise limit for DG sets not covered by the above paragraph:
Noise limits for diesel generator sets not covered by paragraph , shall be as follows:
2.1.2.1 Noise from DG set shall be controlled by providing an acoustic enclosure or by
treating the room acoustically, at the users end.
2.1.2.2 The acoustic enclosure or acoustic treatment of the room shall be designed for
minimum 25 dB (A) insertion loss or for meeting the ambient noise standards, whichever is
on the higher side (if the actual ambient noise is on the higher side, it may not be possible to
check the performance of the acoustic enclosure/acoustic treatment. Under such
circumstances the performance may be checked for noise reduction upto actual ambient noise
level, preferably, in the night time). The measurement for Insertion Loss may be done at
different points at 0.5 m from the acoustic enclosure/room, and then averaged.
2.1.2.3 The DG set shall be provided with proper exhaust muffler with insertion loss of
minimum 25 dB(A).
2.1.2.4 These limits shall be regulated by the State Pollution Control Boards and the State
Pollution Control Committees.
2.1.2.5 Guidelines for the manufacturers/users of Diesel Generator sets shall be as under
01 The manufacturer shall offer to the user a standard acoustic enclosure of 25 dB(A)
insertion loss and also a suitable exhaust muffler with insertion loss of 25 dB(A).
02 The user shall make efforts to bring down the noise levels due to the DG set, outside
his premises, within the ambient noise requirements by proper siting and control measures.
03 Installation of a DG set must be strictly in compliance with the recommendations of
the DG set manufacturer.
04 A proper routine and preventive maintenance procedure for the DG set should be set
and followed in consultation with the DG set manufacturer which would help prevent noise
levels of the DG set from deteriorating with use.

2.1.3 Requirement of Conformance Labelling

(i) The supplier of the ’product’ must affix a conformance label on the product meeting the
following requirements :
(a) The label shall be durable and legible.
(b) The label shall be affixed on a part necessary for normal operation of the ’product’ and not
normally requiring replacement during the ’product’ life.
(ii) The conformance label must contain the following information
(a) Name and address of the supplier (if the address is described in the owner’s manual, it
may not be included in the label)
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(b) Statement "This product confirms to the Environment (Protection) Rules, 1986".
(c) Noise limit viz. 75 dB(A) at 1 m.
(d) Type approval certificate number.
(e) Date of manufacture of the product,

2.1.4 Authorised agencies for certification

The following agencies are authorized to carry out such tests as they deem necessary for
giving certificates for Type Approval and Conformity of Productio’n testings of DG sets and
to give such certificates
i. Automotive Research Association of India, Pune
ii. National Physical Laboratory, New Delhi
iii. Naval Science & Technology Laboratory, Visakhapatnam
iv. Fluid Control Research Institute, Palghat
v. National Aerospace Laboratory, Bangalore

2.2 EMISSION LIMITS FOR NEW DIESEL ENGINES (UP TO 800 KW) FOR
GENERATOR SETS (CENSETS) APPLICATIONS
2.2.1 Emission Limits
The emission limits for new diesel engines up to 800 kw, for gensets applications shall be as
given in the Table below:

TABLE
Capacity Date of Emission Limits (gAcw-hr) for Smoke Test Cycle
of Diesel Implemen- Limit
Engines tation absorption
HC 1CO IPM Torque % Weighting
NO x coefficient,
(WI) (at Factors
full load)

Upto 19kw 1.07.2003 9.2 1.3 5.0 0.6 0.7 100 0.05

1.07.2004 9.2 1.3 3.5 0.3 0.7 75 0.25

>19 kw 1.07.2003 9.2 1.3 5.0 8.5 0.7 so 0.30

upto 50 kw
1.07.2004 9.2 1.3 3.5 0.3 M 25 0.30

>50 kw 1.07.2003 9.2 1.3 3.5 0.3 0.7 10 0.10

upto 260
kw
> 260 1.07.2004 9.2 1.3 3.5 0.3. 0.7,
kw upto
800 kw

2.2.2 Requirement of conformance labelling

(i) All the engines (individually or as part of the product) shall be clearly engraved ’Genset
Engine’ on the cylinder block.
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(ii) The engine or the product must be affixed with a conformance label meeting the
following requirements;
(a) the label shall be durable and legible;
(b) the label shall be affixed on a part necessary for normal operation of the engine or the
product and not normally requiring replacement during the life of the engine or the product.
(iii) The conformance label must contain the following information:
(a) name and address of the engine manufacturer or the engine or product importer (if the
address is given in the owner’s manual, it may not be included in the label);
(b) statement that ’this engine or product conforms to the Environment (protection) Rules,
1986%
(c) type approval certificate number;
(d) date of manufacture of engine or in case of import, the date of import of the engine or the
product.

2.2.3 Compliance with BIS specifications

All engines up to 20 kw (individually or as part of the product) shall carry ISI mark and meet
relevant BIS specifications (IS 1000 1).

2.2.4 Authorised agencies for certification

The following agencies are authorized to carry out such tests as they deem necessary for
giving certificates of Type, Approval and Conformity of Production tests for Diesel engines
and to give such certificates
(i) Automotive. Research Association of India, Pune.
(ii) Vehicle Research and Development Establishment, Ahmednagar.

3.0 References

[1] ISO 10816-3 Mechanical Vibration – Evaluation of machine vibration by

measurements on non-rotating parts.

[2] IS: 12075-1987 (Reaffirmed 1996) Mechanical Vibration of Rotating Electrical

Machines With Shaft Heights 56 mm and Higher—Measurement, Evaluation and Limits of
Vibration Severity.
[3] G.S.R. 371(E)- Environment (Protection) second Amendment Rules, 2002.
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Appendix 1 – Summary of ISO10816-3

ISO 10816-3 Relates to the evaluation of velocity levels measured on the bearings of rotating
machinery. This standard supersedes the previous ISO 2372.

The measuring device must filter and sum the velocity energy between 2Hz and 1kHz, and
the standard only applies to machines with shaft speeds between 120rpm and 15000rpm.

The following Machines are included Machines that are excluded from ISO 10816-3

Steam Turbines < 50MW speed < 1500rpm Steam turbines with speeds > 1500rpm [ISO
Industrial Gas Turbines up to 3MW 10816-2]
Generators Industrial Gas Turbines > 3MW [ISO 10816-4]
Electric Motors Hydraulic units [ISO 10816-5]
Rotary Compressors Machines Coupled to reciprocating parts [ISO
Pumps (non reciprocating) 10816-6]
Blowers or Fans
(Not of lightweight or sheet metal construction)

The summary table inset below shows the maximum severity levels in mm/second and
inches/second RMS for the included machines above within the shown power ranges.

Maximum Allowable levels

ISO 10816-3 mm/sec RMS
CONDITION

Damage >.4.5 > 7.1 > 7.1 >11.0

Restrict
Operation 4.5 7.1 7.1 11.0

Unrestricted 2.8 4.5 4.5 7.1

New
condition 1.4 2.3 2.3 3.5
Rigid Elastic Rigid Elastic
15kW- 300kW 300kW - 500MW

Maximum Allowable levels

ISO 10816-3 in/sec RMS
CONDITION

Damage >0.18 > 0.28 >0.28 >0.43

Restrict
Operation 0.18 0.28 0.28 0.43

Unrestricted 0.11 0.18 0.18 0.28

New condition 0.06 0.09 0.09 0.14

Rigid Elastic Rigid Elastic
15kW- 300kW 300kW - 500MW
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Appendix 1I – Summary of IS:12075-1987

IS 12075-1987 Relates to the evaluation of velocity levels measured on the rotating electrical
machinery.
The current practice followed internationally for measurements of vibration in V rms mode has
been adopted.
This standard is not applicable to machines mounted in situ, three phase commutator
machines, three phase machines operated on single phase system and other coupled
machines.
Measurement of the vibration severity shall be made with the machine at no load and
uncoupled.
Derived values of vibration in displacement amplitude mode have been given for guidance of
those who do not have facility for V rms measurements.
The requirements for instruments for measuring vibration severity are covered in IS:11726-
1985.
Table I: LIMITS OF VIBRATION SEVERITY IN ROTATING ELECTRICAL
MACHINES MEASURED IN STATE OF FREE SUSPENSION

Shaft Height H, mm 56”+” 132<H<225 H>225

Range of Speed, 600 to >1500 upto 600 to >1500 600 to >1500
RPM  1500 3000 1500 upto 3000 1500 upto 3000
Class of Vibration RMS Value of Vibration Velocity, mm/s
Severity
Normal 1.8 1.8 1.8 2.8 2.8 4.5
Precision A 0.71 0.71 0.71 1.12 -- --
Precision B 0.45 0.45 0.45 0.71 -- --
Precision C 0.28 0.28 0.28 0.45 -- --

Table II: DERIVED VALUES OF VIBRATION SEVERITY IN ROTATING

ELECTRICAL MACHINES MEASURED IN STATE OF FREE SUSPENSION

Shaft Height H, 56”+” 132<H<225 H>225

mm
Range of Speed,
RPM 
1000

1500

3000

1000

1500

3000

1000

1500

3000
600

750

600

750

600

750

Class of
Vibration
Severity RMS Value of Vibration Velocity, mm/s
Normal 80 64 48 32 16 80 64 48 32 25 125 100 75 50 42
Precision A 30 24 18 12 6 30 24 18 12 10 - - - - -
Precision B 20 16 12 8 4 20 16 12 8 6 - - - - -
Precision C 13 10 8 5 2.5 13 10 8 5 4 - - - - -

Note :- 1.This table is derived using the formula a=0.45 V rms /f where
a = double amplitude of vibration displacement,
V rms = rms value of vibration velocity measured, and
f = frequency of vibration.
2. Should there be any difference in the test results by two methods, the vibration
limits in rms velocity specified in Table I shall prevail.