YANBU INDUSTRIAL COLLEGE/ MET DEPARTMENT

Dr.M.E.Kassab & Eng.M.Ajmal

Department of Mechanical Engineering technology
YANBU INDUSTRIAL COLLEGE
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Maintenance philosophies
These maintenance philosophies can usually be divided into four
different categories:

1
•Breakdown or run to failure maintenance

• Preventive or schedule-based maintenance

• Predictive or condition-based maintenance

• Proactive or prevention maintenance (RCFA).

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Predictive or condition-based maintenance

l

• Mechanical and operational conditions are periodically monitored, and when unhealthy trends
are detected, the troublesome parts in the machine are identified and scheduled for
maintenance.
• The machine would then be shut-down at a time when it is most convenient, and the
damaged components would be replaced. If left unattended, these failures could result in costly
secondary failures.

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Vibration analysis (detection mode)

Vibration analysis is used to determine the operating and mechanical condition of equipment.
A major advantage is that vibration analysis can identify developing problems before they become too serious and
cause unscheduled downtime. This can be achieved by conducting regular monitoring of machine vibrations either
on continuous basis or at scheduled intervals.

Regular vibration monitoring can detect:

•deteriorating or defective bearings,

•mechanical looseness and
•worn or broken gears.

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Vibration analysis can also detect:

Y
• misalignment and
• unbalance before these conditions result in bearing
or shaft deterioration.

Trending vibration levels can identify poor maintenance practices, such as

improper bearing installation and replacement, inaccurate shaft alignment
or imprecise rotor balancing.

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A vibration analysis system usually consists of four

basic parts:
1. Signal pickup (s), also called a transducer

2. A signal analyzer

3. Analysis software

4. A computer for data analysis and storage.

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What is vibration
Vibration, very simply put, is the motion of a
machine or its part back and forth from its
position of rest.

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VIBRATION+MONITORING+ANALYSIS

Repeated to and fro When and how to

motion of m/c or its measure vibration?
components around the
rest position

The process of
diagnosing the root of
problem after measuring
vibration at different
points of m/c
Sine Sine
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The nature of vibration

A lot can be learned about a machine’s condition and possible mechanical problems by
noting its vibration characteristics. We can now learn the characteristics, which characterize
a vibration signal.

Two main characteristic of vibration 1.frequency

2.amplitude

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Vibration terminology
Vibration displacement (peak to peak)

The total distance travelled by a vibrating part, from one extreme limit of travel to the other extreme limit of travel is
referred to as the ‘peak to peak’ displacement.
• In SI units this is usually measured in ‘microns’ (1/1000th of a millimeter).
• In imperial units it is measured in ‘mils’ (milli inches – 1/1000th of an inch).
Displacement is sometimes referred to only as ‘peak’ (ISO 2372), which is half of ‘peak to peak’.

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Vibration velocity (rms)

The International Standards Organization (ISO), who establishes internationally acceptable units for measurement of
machinery vibration, suggested the velocity – root mean square (rms) as the standard unit of measurement. This was
decided in an attempt to derive criteria that would determine an effective value for the varying function of velocity.

Velocity – rms tends to provide the energy content in the vibration signal, whereas the velocity peak
correlated better with the intensity of vibration.

Crest factor The crest factor of a waveform is the ratio of the peak value of the waveform to the rms
value of the waveform. It is also sometimes called the ‘peak-to-rms ratio’:
Rms=peak/crestfactor
Ex: peak to peak is 18mm/s what is rms?
P-p=18 so (peak to peak=18 so one peak is half of peak to peak)
p is18/2=9mm/s
Rms=9/1.414=6.345

The crest factor of a sine wave is 1.414, i.e. the peak value is 1.414 times the rms value. The crest
factor is one of the important features that can be used to trend machine condition.

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Displacement, velocity, acceleration – which should be

used?
The displacement, velocity and acceleration characteristics of vibration are measured to
determine the severity of the vibration and these are often referred to as the ‘amplitude’ of
Slow speed machine upto 600 rpm use
the vibration. Speed from 600 upto 10000 rpm use velocity medium speed
displacement
machine
High speed machine more than 10000 rpm use
acceleration

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Is Vibration a Problem? Unwanted vibration is a problem

(more than a certain level)
Why machines vibrate at
elevated level?

Machines vibrate due to HIGH VIBRATION

IMPERFECTIONS FORCES(UNWANTED)/PROBLEM
SYSTEM
1. Design S
RESPONSE/
2. Assembly
AMPLIFIERS
3. Manufacture 1. Misalignment
4. Operation 2. Unbalance
1. Resonance
5. Installation 3. Wear (belts, pulleys, bearings,
2. Looseness
6. Maintenance gears)
4. Forces(friction, reaction, hydraulic,
aerodynamic, reciprocating
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5. Acoustic 0
VIBRATION ANALYSIS
 VIBRATION
EQUIPMENT MEASUREMENT
MAINTENANCE

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Handheld vibration meters and analyzers

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Velocity pickup

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Acceleration transducers/pickup

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Displacement probes – Eddy current transducers

proximity probes

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Mounting methods

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FAMILIARIZE YOURSELF TO YOUR EQUIPMENT

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Using vibration theory to machinery fault detection

In Figure, a common machinery train is depicted. It consists of a

driver or a prime mover, such as an electric motor. Other prime
movers include diesel engines, gas engines, steam turbines and gas
turbines. The driven equipment could be pumps, compressors,
mixers, agitators, fans, blowers and others. At times when the driven
equipment has to be driven at speeds other than the prime mover, a
gearbox or a belt drive is used.

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Each of these rotating parts is further comprised of

simple components such as:
• Stator (volutes, diaphragms, diffusers, stators poles)

• Rotors (impellers, rotors, lobes, screws, vanes, fans)

• Seals

• Bearings
• Couplings

• Gears

• Belts.

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Common defects that cause high vibrations levels in machines

are:
• Unbalance of rotating parts
• Misalignment of couplings and bearings
• Bent shafts
• Worn or damaged gears and bearings
• Bad drive belts and chains
• Torque variations
• Electromagnetic forces
• Aerodynamic forces
• Hydraulic forces
• Looseness
• Rubbing
• Resonance.(resonance is asound which is produced by an object when it vibrates at
the same rate as the sound waves from another object)

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Class I
Individual parts of engines and machines integrally connected with a complete machine in its normal
operating condition (production electrical motors of up to 15 kW are typical examples of machines in this
category).

Class II
Medium-sized machines (typically electrical motors with 15–75 kW output)
without special foundations, rigidly mounted engines or machines (up to 300 kW) on special foundations.

Class III
Large prime movers and other large machines with rotating masses mounted on rigid and heavy
foundations, which are relatively stiff in the direction of vibration.

Class IV
Large prime movers and other large machines with rotating masses mounted on foundations, which are
relatively soft in the direction of vibration measurement (for example – turbogenerator sets, especially
those with lightweight substructures).

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General machinery
severity chart

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VIBRATION ANALYSIS
(DIAGNOSTIC)

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AMPLITUDE : MAXIMUM VALUE FROM THE MEAN

POSITION
Displacement/Velocity/Acceleration
It indicates the
severity of vibration

EVERY COMPONENT/PART OF THE MACHINE HAS ITS OWN FREQUENCY OF

VIBRATION !!!! SIGNATURE
FREQUENCY : NUMBER OF CYCLES PER UNIT TIME (CPS/Hrtz)

It acts like an ID # of the

vibrating part
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HOW THE SIGNAL IS ANALYZED?

MOST OF THE TIME SIGNAL IS A COMPLEX WAVEFORM IN TIME

DOMAIN
THERE ARE TWO TYPES OF VIBRATION
SIGNALS
1 time domain 2.frequency domain

SIGNAL IN FREQUENCY
SIGNAL IN TIME
DOMAIN
DOMAIN

TIME SPECTRU
SIGNAL M

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Amplitude
Heavy Spot Time Waveform
+

0 Time

360 degrees
-

Rotation 1 revolution
3600 rpm = 3600 cycles per minute
60 Hz = 60 cycles per second
1 order = one times turning speed

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Time Waveform
Amplitude
+

0 Time

-
1 revolution
1000 rpm
4 blades = vibration occurs 4 times per revolution
4 x 1000 rpm = vibration occurs at 4000 cycles per minute
= 4000 cpm

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Time Waveform
Amplitude

Time
0
12 tooth
gear
-

1 revolution
1000 rpm
12 teeth are meshing every revolution of the gear

12 x 1000 rpm = vibration occurs at 12,000 cycles per minute

= 12,000 cpm = 200 Hz
60 CPM=1HZ
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0 Time

0 Time

+
0 Time
-

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Complex Time Waveform

Time Waveform contains all the different frequencies mixed
together
+

0
Time

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Complex Time Waveform

Time Waveform contains all the different frequencies mixed

together

YIC/ MET 213 / Dr.Kassab & Eng.M.Ajmal VIBRATION ANALYSIS

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Signal Processing Flow

FFT-FAST FOURIER
Transducer
TRANFORMATION
Waveform
A
m
pli
tu
de
Time

FFT
Spectrum
A
m
pli
tu
de
Data Collector/Analyzer Frequency

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A TYPICAL SPECTRUM
1xRPM - BALANCE
1.8

1.5 2xRPM -
ALIGNMENT
1.2
3-5xRPM - LOOSENESS
0.9
ANTI-FRICTION BEARINGS & GEARMESH
0.6
5-25xRPM 25-65xRPM
0.3

5000 10000 15000 20000

Frequency Hz

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Portable data collectors/analyzers

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We are now entering the Frequency Domain

• FFT - Fast Fourier Transform

• Separates individual frequencies

• Detects how much vibration at each frequency

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Rolling element bearings

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1. Write any three imperfections which lead to the machine vibration at elevated level

2. For the given machine at some instance of operation the vibration spectrum is shown below. Find out
the nature of problem/s and its location.

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Bearing NUMBER Number of balls Ball diameter Bearing diameter Angle θ

Nb Bd Pd
6013 SKF 15 10.3mm 82.5mm 0

1. Calculation of RPM for every shaft

2. Calculation of expected vibration frequencies of gears, fan and the given bearing

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Expected Problem: BEARING

Expected Problem: FAN

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Expected Problem: GEAR

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PART 1 PROBLEM:
Expected frequency=(RPM of the rotating shaft/60)*1------------------for disc
Expected frequency=(RPM of the rotating shaft/60)*number of teeth ----------------for gear
Expected frequency=(RPM of the rotating shaft/60)*number of blade ---------------for fan
Expected frequency=(RPM of the rotating shaft/60)*number of bolt for rigid coupling
Expected frequency=(RPM of the rotating shaft/60)*spokes (inside line of pulley) for pulley

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Example: for disc speed 1800 rpm

Expected frequency=(1800/60)*1
Expected frequency=30 Hz
This 30 Hz is 1X for u
Then 2X=30*2=60 Hz
3X=30*3=90Hz and so on.

First find what is the vibration limit from the graph see first it lies in which class if power is
given below 15 kw then it lies in class 1 machine so select class 1 machine.so see upto need
improvement value that is 4.5 mm/s this is your limit

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now the graph shows it cross the limit so there is vibration there.
now take another example

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Now 1x and 2x cross the line but 3x does not cross so neglect 3x just take 1x and 2x .Then go to the reference
guide there u can see that 1X & 2x A,R&T(AXIAL ,RADIAL,TANGENTIAL) IN ALL THE THREE IF IT
CROSS THE REFERENCE LINE THEN THE PROBLEM IS COMBINATION OF PARALLEL AND
ANGULAR MISALIGNMENT

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1.The p-p value of the vibration signal is 18 mm/s, calculate RMS value
18/2*0.707= 6.4MM/S
RMS=Peak*0.707
But he is saying peak to peak so peak is half of peak to peak 18/2 is peak 18 is peak
to peak

2.Rearrange the following mechanical problems of a centrifugal pump in a sequence to

complete its maintenance.
Bent Shaft, Bearings damaged, Packing failure, Wear Ring replacement, Misalignment,
Field balancing of Impeller, Gasket replacement, Reassembly

Answer)
Bent Shaft, Bearings damaged, Wear Ring replacement , Gasket replacement,
Reassembly ,Packing failure, , Misalignment, Field balancing of Impeller
Note: balancing should be done at the last

Peak/1.41
4

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1.Calculate the Amplitude value of the vibration signal having rms value of 6.2 mm/s.
6.2/0.707 = 8.77 mm/s
2.Write any three machine problems that can be detected by vibration analysis.
•Looseness
•Rubbing
•Resonance.
•Unbalance of rotating parts
•Misalignment of couplings and bearings
•Bent shafts PD=20+47/
2 can be measured.
3.Write any three units in which vibration
mm, mm/s, mm/s2 , inch, mils, inch/s

4. Define crest factor of a vibration signal.

The crest factor of a waveform is the ratio of the peak value of the waveform to the rms
value of the waveform.

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