M A C H I N E R Y M E S S A G E

10 ORBIT 2Q04
Enveloping is a tool that can give
more information about the life
and health of important plant
assets. It is primarily used for early
detection of faults in rolling
element bearings and gearboxes.
Enveloped acceleration is an espe-
cially valuable parameter to trend,
as the progression of machine con-
dition can be evaluated. Armed
with good information and assisted
by Bently Nevada service experts,
plant engineers can be confident in
the proper operation and man-
agement of the important assets
under their care.
Enveloping can reveal faults in
their earliest stages of devel-
opment, before they are detectable
by other machinery vibration
measurements. Without an early
fault detection technique like
enveloping, personnel must wait
until the latter stages of failure,
when overall vibration increases,
lubricants become contaminated,
and temperatures rise. By this time,
the remaining usable life of the
failing machine elements could be
very short and the damage more
extensive than if the fault had been
detected earlier.
The enveloping technique enables
the detection and analysis of low-
level, repetitive vibrations by
extracting them from the overall
machinery vibration signal.
Enveloping thus facilitates earlier
prediction of failure in machines
with metal-to-metal contact.
While the examples in this article
are based on rolling element
bearings, the techniques also can
be applied to gearboxes and electric
motors with commutators.
It is important to note that the suc-
cessful application and interpre-
tation of enveloping data require
experience. Enveloping is just one
tool in the analyst's toolbox, and it
is best used as one of a number of
techniques for complete moni-
toring of a machine.
Nathan Weller
Senior Engineer
GE Energy
e-mail: [email protected]
Acceleration Enveloping
Higher Sensitivity, Earlier Detection
M A C H I N E R Y M E S S A G E
2Q04 ORBIT 11
Band-pass
filtering
Spectral
analysis
Low-pass
filtering
Enveloping Rectification
Frequency
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Seismic
transducer
Structural ringing
Seismic
transducer
Bearing
support
structure
Structural
resonance
Repetitive
defect
impact
Defect
Rolling
element
Outer O
ring
TYPICAL STEPS IN THE IMPLEMENTATION OF ENVELOPING. | FIG. 1
Enveloping Isolates
Signals of Interest
Enveloping is a multiple-step
process that extracts signals of
interest from an overall vibration
signal (Figure 1). In a rolling
element bearing, the interaction
between bearing elements and
defects excites a structural reso-
nance in the bearing support
structure. A seismic transducer
measures the vibration, and this
signal is band-pass filtered to keep
only signal components around
the resonance frequency. The fil-
tered signal is rectified and then
enveloped, which removes the
structural resonance frequency and
preserves the defect impact fre-
quency. A low-pass filter then elim-
inates some of the extraneous
high-frequency components, and
a spectrum is generated. Frequency
components are correlated with
physical bearing parameters, and a
trend of the spectra can show pro-
gression of defects.
Analysis of the enveloping process
begins with the source of the
vibration signal. As the elements of
M A C H I N E R Y M E S S A G E
12 ORBIT 2Q04
the bearing interact with each other
and with defects, forces are coupled
to the machine casing, producing
vibration. These defect interactions
behave as impacts that excite a
natural resonance frequency of the
machine, causing it to ring (Figure
2). The amplitude of the ringing
decays until the next impact, which
re-excites the resonance. Thus, the
defect amplitude modulates the
natural resonance response at the
impact frequency. The defect-
related signal becomes part of the
overall vibration of the machine.
Because of its higher frequency
response characteristics, an accel-
erometer is generally used to
measure the vibration signal for
enveloping. Thus, enveloping is
often called acceleration envel-
oping or high-frequency acceler-
ation enveloping. High-frequency
vibration signals, such as the reso-
nance carrier of the defect signal,
do not travel far in a homogeneous
machine structure; metal imperfec-
tions, joints, and gaskets cause
further significant attenuation
(Figure 3). It is critical that this
low-level, high-frequency signal be
coupled efficiently into the
accelerometer; the accelerometer
should be mounted as close to the
bearing as possible and near the
load region of the bearing, where
signals are coupled more effectively
to the machine case.
The output of the accelerometer
(Figure 4) contains three important
frequencies: a relatively low-
frequency, high-amplitude rotor-
related vibration; the modulated
structural resonance frequency;
and other high-frequency vibration
components, including harmonics
of the structural resonance fre-
quency. Though the signal is
complex, application of the
enveloping technique allows us to
determine an impact frequency
associated with the defect, which
provides valuable information
about machine condition.
Structural
ringing
Defect
Seismic
transducer
Rolling
element
Rolling
element
train
direction
Outer ring
DEFECT IMPACT CAUSES RINGING OF THE MACHINE STRUCTURE AT ITS
NATURAL FREQUENCIES. | FIG. 2
( c ont i nued on page 16)
M A C H I N E R Y M E S S A G E
2Q04 ORBIT 13
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
Distance from vibration source
S
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s
t
r
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t
h
Loss in
nonhomogeneous
material
Interface loss -
outer ring to
bearing support
Loss in homogeneous
material
Interface loss -
transducer mounting
VIBRATION SIGNAL TRANSMISSION LOSS IN HOMOGENEOUS AND
NONHOMOGENEOUS MATERIALS. | FIG. 3
Time
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ACCELEROMETER VIBRATION WAVEFORM OUTPUT WITH EMBEDDED DEFECT SIGNAL. | FIG. 4
M A C H I N E R Y M E S S A G E
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Implementing an Enveloping Program:
What Are the Issues?
A SIDEBAR ARTICLE
3
2
1
4
While the methodology for generating an enveloping spectrum may seem straightforward, valid results
depend on careful application. Consider the following eight issues before applying enveloping techniques to
machinery monitoring:
EARLY DETECTION: Enveloping provides early detection of faults that would otherwise be obscured by larger
components of the machines vibration signature. However, when a fault is identified in an enveloping
spectrum, failure is not necessarily imminent, but monitoring of that machinery component should be
increased to trend progression of the fault. Defects will not be detectable until they have progressed to the
point that their interaction with other components is repetitive, not random. Check against other data using
other measurement techniques, as available.
ELIGIBLE MACHINES: Enveloping techniques can be used to detect faults in machine components with repet-
itive metal-to-metal interaction. However, because enveloping is not a direct measurement, many extra-
neous factors can add to or diminish the enveloped signal. Several machine components or characteristics can
prevent successful enveloping implementation. Joints, interfaces, gaskets, and fluid-film or squeeze-film
dampers prevent high-frequency signal transmission critical for enveloping. High-frequency operational noise
may overshadow signals of interest in reciprocating machines, variable frequency drive motors, and others.
Electromagnetic interference may also introduce itself into the cabling between the transducer and the signal
processing device and compromise signal integrity.
TRANSDUCER SELECTION: The frequency response of the transducer must include the expected range of
machine resonance frequencies (ranging from 1 kHz to more than 40 kHz). The resonance frequency of the
mounted transducer must be sufficiently far away from the machine frequencies of interest to avoid interac-
tions. The transducer should be extremely reliable to ensure trending consistency.
TRANSDUCER MOUNTING: Enveloping measurements are highly dependent on transducer mounting method
and location. Even a slight change in mounting location can yield quite different results, so a solid, repeatable
mounting is essential to help ensure that changes observed in data are due to changes in machine condition
not just variations introduced by the person collecting the data. A flat, clean (bare metal) surface for mounting
the transducer is critical. Handheld transducer applications can be especially susceptible to variation based on
changes in applied pressure, mounting angle, and other variables introduced by the person taking the reading.
For this reason, use extra care when handheld transducers are used for enveloping measurements. When
practical, consider affixing the transducer in a way that reduces variability such as by screwing it onto the
measurement surface using a mounting stud, or if using a handheld "stinger" assembly develop a routine
of holding it in the same manner, applying the same pressure, and orienting it at the same angle (perpendi-
cular to the measurement surface) for every data collection location. Since the high frequency signal on which
enveloping depends does not usually travel very far within a machine, the transducer mounting should have a
short transmission path from the machinery component of interest, with as little damping of the high fre-
M A C H I N E R Y M E S S A G E
2Q04 ORBIT 15
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quency energy as possible. Any metal interface or discontinuity in the machine causes significant signal atten-
uation, and fluid films at any interface can completely stop transmission of a signal. Consequently, faults
which are detected with enveloping can be expected to be located near the measurement transducer.
FAULT IDENTIFICATION: Because of the correlation between fundamental spectrum frequencies and
fault sources, flawed components can often be identified before the bearing is removed and physi-
cally examined, allowing spare parts to be ordered in advance and work procedures to be written
with the knowledge of precisely what needs to be changed. Frequencies associated with the
machines components and its natural resonances must both be considered when configuring the
enveloping technique to ensure valid data. Since improper lubrication, caused by inadequate,
excessive, or contaminated lubricants, can cause frequency components to appear in the enveloping
spectrum, lubrication should be checked first when faults appear. Progression of faults is often
indicated by the presence of more bearing frequency components and an overall increase in the
noise floor of the enveloping spectrum. Overall, the fundamental fault frequencies in the spectrum
are the most important for correlation with physical defects.
SEVERITY PREDICTION: Enveloping provides valuable information for machinery management.
However, enveloping by itself does not give all the information necessary for reliable and accurate
prediction of the condition of a machine component, such as a bearing or gear. In the enveloping
spectrum, frequency can be correlated to a specific machine component, but increasing magnitude
is not necessarily correlated to the progression of the fault. In fact, a well-known phenomenon is
that the acceleration enveloping amplitude may actually decrease as bearing failure becomes more
imminent. As a bearing continues to wear, its small, vibration-inducing flaws begin to smooth out,
and the characteristic ringing caused by the flaws (and detected by enveloping) decreases. When
enveloping data is used with other measurements, such as direct machine vibration, acoustical
noise levels, and temperature, machinery condition can be more accurately determined.
TRENDING CONSISTENCY: Data must be collected periodically and consistently to ensure the integrity
of the trend. As noted in point #4, this includes using the same transducer in the same location
mounted the same way to reduce gross and systematic errors. Then the trend can be evaluated to
see the progression of any defects. Permanently mounted transducers are recommended.
FREQUENCY VARIATION: The absolute frequency of enveloping signals is directly dependent on shaft
rotation speed. In order for frequencies to be correlated with potential faults, machine speed must
be known and relatively constant. Otherwise, the magnitude of frequency components may be
affected by frequency-dependent machinery and instrumentation responses rather than changes
in defect severity.
M A C H I N E R Y M E S S A G E
16 ORBIT 2Q04
Filtering an Important Part
of Enveloping Process
Band-pass filtering is the first signal-
processing step in the application of
the enveloping technique. Proper
filter specifications are critical to the
removal of unwanted components of
the signal while preventing detri-
mental attenuation of signal compo-
nents essential for enveloping analysis.
Frequency range selection must take
into account machine operating
speeds and structural natural fre-
quencies, which depend, at least in
part, on bearing design along with
machine construction and mounting.
In order to get the best (most useful)
information from the enveloping
technique, some experimentation
with available frequency ranges for the
filters is often required when
enveloping is first applied.
A good starting point is to examine
the spectrum plot for a high-
frequency, structural resonance hay-
stack. The lower corner (high-pass
corner) should be set above gear mesh
frequencies, but below this structural
resonance haystack. The lower
corner frequency is selected to reject
the comparatively high-amplitude,
low-frequency components that are
associated with the normal machine
running speed vibration. This greatly
improves the signal-to-noise ratio for
the frequencies of interest, since it is
these lower frequencies that generally
dominate the vibration signal. The
upper corner frequency is selected to
remove extremely high frequencies
which are associated with other
machine vibration frequencies and
signals amplified by the accelerometer
or mounting resonance.
For a machine with rolling element
bearings, the lower corner frequency
is generally set to be greater than ten
times the running speed of the
machine (10X) to eliminate the most
common harmonics of running
speed. However, this frequency
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BAND-PASS FILTERED VIBRATION WAVEFORM SHOWING DEFECT MODULATION OF THE
MACHINE STRUCTURAL RESONANCE. | FIG. 5
( c ont i nued f r om page 12)
M A C H I N E R Y M E S S A G E
2Q04 ORBIT 17
should not exceed one-half of any
structural natural frequency asso-
ciated with the bearing. This
natural frequency serves as the
carrier frequency excited by the
defect impacts, and attenuating
this signal of interest is detrimental
to the success of enveloping.
The upper corner is generally set to
around sixty times the outer-race
ball-pass frequency (60X BPFO),
or approximately two hundred
times running speed (200X). This
attenuates high frequency noise
and vibration components, some
of which have been amplified by
accelerometer resonances. These
basic rules are relatively simple to
apply to a rolling element bearing.
However, on a gearbox they
become more complicated because
of gear-mesh frequencies.
The band-pass filter output
(Figure 5) shows the structural res-
onance frequency, which is the
higher frequency in the waveform,
modulated by the defect. The
impacts associated with the defect
excite this carrier frequency, and its
amplitude then decays exponen-
tially. The signal from a defective
bearing may have different impact
intervals, more frequency compo-
nents, and differing amplitudes
all potentially influenced by lubri-
cation, the number of defects, the
severity of the defects, and the
loading of the bearing (among
other things). However, enveloping
is still effective and even more
valuable for these more compli-
cated signals.
Amplitude Demodulation
Eliminates the Resonance
Frequency
To envelope (demodulate) the
filtered signal, it first is full-wave
rectified (Figure 6), which doubles
the carrier frequency and further
separates the impact frequency and
the carrier frequency.
The next step is the actual
enveloping itself. Amplitude
demodulation of the rectified
waveform eliminates the carrier
frequency and leaves the repetition
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FULL-WAVE RECTIFIED VIBRATION SIGNAL. | FIG. 6
M A C H I N E R Y M E S S A G E
18 ORBIT 2Q04
rate of the defect impact. A number
of methods are available to accom-
plish demodulation, including peak
detection (Figure 7), integration,
and low-pass filtering.
Generally, enveloping results in a
waveform which has spectral com-
ponents corresponding to the
defect impact frequencies and, due
to the impact nature of the event,
harmonics of the defect fre-
quencies. Frequency components
unrelated to the impact will gen-
erally be of higher frequency than
the components of interest. Some
of these can be eliminated by
another application of low-pass fil-
tering, leaving the defect impact
frequencies and some low-order
harmonics. Interpretation of this
less-cluttered spectrum is easier,
since fewer components need to be
considered.
The next step before analysis is to
generate a spectrum of the
enveloped signal. The defect impact
frequency should show up clearly
in relation to all the other spectral
components in the signal.
Harmonics of fundamental fault
frequencies are generally artifacts of
the enveloping process and are not
valuable for trending purposes,
except that the presence of more
harmonics may indicate the pro-
gression of a fault. After disre-
garding harmonics, significant
frequencies present in the spectrum
may be correlated to physical
machine parameters. Note that,
especially as defects become more
severe, sidebands related to running
speed may appear around defect
frequencies in the spectrum.
If uncorrelated frequencies are
present in the spectrum, the filters
may have been configured incor-
rectly or the transducer measure-
ments were taken improperly.
Frequencies may also come from
other nearby machinery compo-
nents, or they may be caused by the
machine operation or process.
While improper measurement
techniques may prevent frequencies
from appearing in the spectrum, if
defects are absent in the monitored
machinery, then no defect-asso-
ciated frequency components
should be seen in the spectrum.
Interpretation of Information
Is Final Step
Interpretation of the information is
the very important final step.
Trending the magnitude of these
frequency components can indicate
the progression of bearing faults,
but the magnitude is not necessarily
related to the severity of the defect.
For example, developing faults,
such as a spall, may initially cause
defect frequencies that have
increasingly larger amplitudes. As
the spall grows, it may present less
of an impact event as the edges of
the fault self-peen, or smooth
themselves out; the amplitudes now
decrease. A measurement trend is
therefore valuable to show the
phases through which the signal has
gone and to allow the user to infer
the progression of the fault.
For trending of defect frequencies
to be useful, baseline information
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peak detector output
full-wave rectified signal
ENVELOPE OF VIBRATION SIGNAL PRODUCED BY A PEAK DETECTOR. | FIG. 7
M A C H I N E R Y M E S S A G E
2Q04 ORBIT 19
is required. It must be taken when the
bearing is known to be in good condition
and often enough to provide adequate reso-
lution of the progression of the fault. In
addition, initial experimentation with filter
settings will help validate data. Knowledge
of the machine and its bearings is essential
to identify the frequencies to monitor.
Because successful trending and correlation
of data requires repeatable measurements,
permanently mounted transducers are rec-
ommended.
Proper Installation, Application, and
Experience Make Enveloping Work
When properly applied, enveloping can be
a valuable tool for early detection of faults
in machines with rolling element bearings
and gearboxes. It is especially useful when
applied in a periodic monitoring schedule
and can provide condition information indi-
cating faults in their earliest stages of devel-
opment. With the help of Bently Nevada
solutions and services, including enveloping
techniques, machinery availability and relia-
bility are more certain, and personnel can
be more confident of the mechanical con-
dition of the assets under their care.
In summary, to use enveloping techniques
successfully, care must be taken in a variety
of areas. Experience is extremely valuable.
Machinery knowledge is critical. Proper
configuration of the whole measurement
system is essential. Equipment selection and
application must be done with all these con-
siderations in mind, and while a good
product will make the use of enveloping
easier, it is never a mindless exercise.
Enveloping must be used with its capabil-
ities and limitations in mind so that, if this
is done, it can be a useful tool in the hands
of a capable machinery analyst.
Editors Note: See also our article on page 58 for a
case history on enveloping techniques in wind
turbines.
Enveloping Now Supported in
Selected Bently Nevada Products
The acceleration enveloping capabilities described in this
article are now available in the following Bently Nevada
products:
Snapshot

for Windows

CE portable data collector

Snapshot

IS portable data collector

Trendmaster

Pro Dynamic Scanning Module and

selected Transducer Interface Modules (TIMs)
These hardware devices can be configured to provide
acceleration enveloping and other signal processing func-
tions that are particularly useful for managing machinery
with rolling element bearings. Each is supported by System 1

software where acceleration enveloping data can be dis-

played, archived, and trended. In addition, basic level-type
alarms can be established on various aspects of the envel-
oped data. By adding System 1 softwares Decision Support
SM
capabilities, you can even configure powerful rules that
embed your own intelligence and machinery knowledge
to automatically analyze enveloping data, spectral data,
and other machinery and process measurements (temper-
ature, oil condition, etc.). These rules can then generate
customized, Actionable Information

advisories that
streamline maintenance activities by providing proactive
and intelligent information, enhanced by the early warning
capabilities that acceleration enveloping can provide.