CONDITION MONITORING

VIBRATION ANALYSIS AND IN-SITU BALANCING

VIBRATION:
It is the motion of mechanical parts back and fort from its position of rest/neutral position.
Causes of Vibration:
Forces generated within the machine causes vibration.
Most common machinery problems that cause vibration include:
Mis alignment of couplings, Bearings and gears.
Unbalance of rotating components.
Looseness.
Deterioration of Rolling Element Bearings.
Gear Wear.
Rubbing.
Aerodynamic/hydrodynamic problems in fans, blowers & pumps.
Electrical problems (Unbalance magnetic forces) in motors.
Resonance.
Eccentricity of rotating components such as “V” Belts pulleys or gears.

COMPARISON OF MAINTENANCE PHILOSOPHIES:

In general there are 3 ways to maintain machinery.
1. BREAK-DOWN MAINTENANCE.
2. SCHEDULED OR PREVENTIVE MAINTENANCE.
 3. PREDICTIVE MAINTENANCE

BREAK-DOWN MAINTENANCE:
Break down maintenance is essentially no maintenance at all. The machine
is simply allowed to run until complete failure, inefficiency or product spoilage forces a shut-down.

SCHEDULED OR PREVENTIVE MAINTENANCE:

Compared to break down maintenance, a program of periodic disassembly
inspection & replacement of worn parts has a good advantage of lessening the frequency of break-down repairs
and also permits scheduled shut-down.
Under this program each critical machine is shut-down after a specific period of operation and
partially or completely dismantled for a thorough inspection an replacement of worn out parts-if any.

PREDICTIVE MAINTENANCE:
Predictive maintenance involves the trending and analysis of machinery
performance parameters to detect and identify developing problems before failure and extensive damage.

Vibration can takes place in 3 directions i.e Horizontol,Vertical,Axial.

Note: Generally in vertical direction vibration amplitude value is low, because weight of the machine is acting
on it.
If it occurs that vibration is high in vertical direction we can conclude that major problem is there in the
rotating body.
By keeping transducer in the 3 directions vibration is captured individually .
The purpose of vibration is to identify effects and evaluate machine condition.

Amplitude of vibrating motion are described using the following units.

Displacement,mils-peak to peak (1000 mils= 1 inch)
Velocity, in/sec-peak or rms ) IRS=peak or mm/sec
Acceleration ,g’s= peak or rms (3816.1 in/sec2=1g)

Frequency=CPM cycles/minute ,cycles/hz

Phase is expressed in(deg) in which one revolution of a shaft or one period of revolution.
Speeds are expressed in revolutions/minute (RPM)
VELOCITY(mm/sec): Velocity is the time rate of change of displacement. It is dependent on both displacement
and frequency.
VIBRATORY MOTION:
The fundamental characteristics of vibration are Frequency, amplitude and phase.

Frequency: Frequency is defined as no of cycles or events per unit time.

Amplitude: Maximum value of vibration at a given location on the machine.
Phase: Phase is the time relationship mentioned I degrees.

Vibration Standards:

Machinery Classification in accordance with ISO 2372.

CLASS I : Individual parts of engines and machines, Integrally connected with the complete machine in its
normal operating.(Production electrical motors of upto 15 KW.)

CLASS II : Medium sized machines ,(typically electrical motors with 15 to 75 KW output) without special
foundations ,rigidly mounted engines or machines(upto 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 direction of vibration measurement.

CLASS IV : Large prime movers and other large machines with rotating masses mounted on foundations which
are relatively soft in direction of vibration measurement (e.g. ,turbo generator sets, especially those with light
weight sub structures.)

For Example:
Recommended values of vibration values of class1 & class2 machines are given in below table.

Class-I machines
 SL GRADE PEAK
NO VALUE(mm/
sec)
01 A 1.0-1.58
02 B 1.58-2.5
03 C 2.5-6.4
04 D 6.4-25

Class II Machines:

SL GRADE PEAK
NO VALUE(mm/
sec)
01 A 1.10-1.58
02 B 1.58-4.00
03 C 4.00-10.00
04 D 6.4-25
Where A: GOOD, B: ROUGH, C: STILL ACCEPTABLE, D: UN ACCEPTABLE

STEPS FOR ANALYSIS

`1.Prepare a rough sketch of the machine to be analyzed.
2. Fill up the table below.
 Displacement, Velocity (mm Acceleration,
(mu) /sec) (g)
H V A H V A H V A
01
02
03
04
05
06
3. Note down the rpm ,Kw, foundation load and operating parameters.
4. Note down the engineering parameters ,Bearing No, Coupling details etc.
5. Note down maintenance recently done on the machine.
6. Physically observe the machine.

GENERAL GUIDE LINES (for Velocity)

1. If “ H” is higher –Most likely “Unbalance for simply supported rotors, for over hung rotors unbalance
produces high axial vibrations also.
2. If “V” is high –most likely Looseness.
3. If “A” is high ,Most likely Misalignment, bearing defect, bent shaft etc.
4. If “H” & “A” is high, Good indicator of mis-alignment.

BASIC CHECKS
1. Compare “H” &”V” ………..”V” should not be more than 25% of “H”.
2. Vertical “V” should be same everywhere.
 3. Axial should not be more than the 50% of highest radial(H/V).

For correction, alignment tolerances:

SL Machine RPM Tolerance(mm
NO )
01 <1000 0.08-0.11
02 1000-2000 0.05-0.10
03 2000-4000 0.025-0.05
04 4000-6000 0.013-0.025

Overall Velocity Guide lines for Vibration severe vibrations

Overall Classification Description
Vibration
Velocity Pk
0-1.00 VERY SMOOTH Exceptional. Extremely well balanced ,well aligned equipment. Make
mm/sec routine periodic checks.

1 to 3 SMOOTH Well Balanced. Typical of well balanced, well aligned equipment. Make
mm/sec routine periodic checks

3 to 5 AVERAGE Minor faults. Continue routine periodic checks.

mm/sec

5 to 8 SLIGHTLY ROUGH Faults likely. Make detailed vibration analysis. Continue. periodic
mm/sec checks. Schedule repair as necessary
8 to 15 ROUGH Potentially damaging vibration. Make detailed vibration analysis to
mm/sec identify trouble .Rapid wear expected Make more frequent periodic
checks. Schedule for repair
15 mm & VERY ROUGH Severe vibration, potentially unsafe. Make immediate detailed
up vibration analysis to identify trouble Excessive vibrations may cause oil-
film break-down . Consider shut-down to avoid in–service failure
VIBRATION FREQUENCIES AND LIKELY CAUSES.

Most likely
Frequency in causes Other possible causes and remarks
terms of RPM

1.Eccentric journals, gears or pulleys.

1X RPM Unbalance 2.Misalignment or bent shaft-if high axial vibration.
3.Bad belts if RPM of belt.
4.Resonance.
5.Reciprocating forces
6.Electrical problems.
2Xrpm Mechanical 1.Mis alignment if high axial vibrations.
Looseness 2.Reciprocating forces.
3.resonance.
4.Bad belts if 2x RPM of belt.
3Xrpm Misalignment Usually a combination of misalignment and excessive axial
clearances(looseness)
 Less than 1XRPM Oil whirl(less 1.Bad drive belts.
than ½ rpm) 2.back ground vibration.
Bad Gears 3.Sub harmonic resonance.
Many times Aerodynamic Gear teeth times RPM of bad gear
RPM(Harmonically Forces Number fan blade times RPM
Related Hydraulic Number of impeller vanes time RPM
frequency) forces May occur at 2,3,4 and sometimes higher harmonics if severe

Mechanical looseness

Looseness

Bent Shafts:
Caused by:
Manufacturing errors
Mis handling during operation
Bow due to thermal growth.
Rotors can be kinked or bowed.
Vibration Analysis
Bent Shafts:
1 High Axial Vibrations (Greater than 50% of the Axial Vibration)
2. 1*, 2* rpm normally high.
3. Dominant Vibration normally at 1* rpm if bent near shaft center, but at 2* if bent near coupling.
Misalignment:
1. Biggest problem initially.
2. Operating temperature can effect alignment, machines cold can go out when warm
3. Bases or foundations can settle
4. Grouting can shrink or deteriorate.
5. Forces shared by driver and driven (not localized).
6. Level of misalignment severity.

There are three types of misalignment namely

1. Angular misalignment.
2. Parallel misalignment &
3. Combination (most common)
.General Characteristics of misalignment:
1. High Axial Vibration at 1X RPM
2. Radial Vibrations is Highly directional.
3. 1X, 2X, 3Xrunning speed depending on type and extent of misalignment
Angular 1Xrpm axial
Parallel 2Xrpm radial (H&V)
Combination 1, 2,3X rpm radial and axial.
Angular misalignment:
1 .High axial Vibration (Greater than 50% of the radial vibration).
2. 1x, 2X, 3X RPM normally high.
3. Severe misalignment will generate 1X, 2X, 3X peaks.
Offset misalignment:
1 Low axial vibration in comparison to Angular .Also shows high radial vibrations.
2. 1x, 2X, 3X RPM .2X often larger than 1X.
3. Incase of severe misalignment much high harmonics (4X-8X) or even a whole series of high frequency
harmonics will be generated.
Parallel or offset misalignment:
1. Perodices a predominant 2X rpm peak in the spectrum.
2. Severe conditions will produce 2X, 4X, 6X.
Looseness:
There are two types of looseness
1. Looseness of rotating systems.
2. Looseness of support system.
Generally looseness is not an exciting force, only it allows exciting frequencies already present to exhibit much
higher amplitudes.
Loss or reduction in normal stiffness. Caused by
Loose mounting bolts
Deterioration of grouting.
Crack welds.
Looseness of rotating systems:
Loose Rotors,
Bearing loose in the shaft or housing,
Excessive sleeve bearing clearances.
Looseness of support system

Loose mounting bolts,

Grouting deterioration,
Cracks,
 Poor support,
Frame distortion.
Mechanical Looseness (Support System)
Caused by structural weakness of machine feet, base plate or foundations, also deteriorated grouting, loose
Hold-Down bolts and distortion of the frame or base.
Radial Vibration high
1XRPM dominant.
180edg Phase difference between mating surfaces which have looseness between them.
Looseness of support system identified by
Highly directional vibration
Bouncing
Taking comparative phase readings across interfaces and look for
amplitude vibration
Typical loose in vertical direction.
Caused by looseness in bearing housing bolt, Radial vibration high.
2X RPM normally dominant.0.5X and 1X RPM may also be present
180 deg phase difference between mating surfaces which have looseness between them.
Looseness due to rocking motion or cracked structure/Bearing Pedestal
2X RPM normally dominant
0.5X, 1X & 3X RPM may also be present.
Bearing loose in housing.
Excessive internal bearing clearances .
Multiple running speed harmonics sometimes up to 10X or even 20X RPM are clearly present in the spectrum.
Vibration on Bearings and gears:

Only 10 to 20% of all Bearings achieve their design life.

Being replaced too often……….
Wrong Lubrication.
Mixing in compatible lubricants.
Too much or too little lubricant.
Presence of contaminant in lubricant.
Misalignment
Distorted Housing bore.
Inadequate internal clearance.
Distorted seals.
Under sized shaft diameter.
Improper application.
Improper storage.

Rolling Element Bearing failure modes.

Rolling element or races fail by fatigue stress giving pitting.
Over heating due to poor fitting or over greasing.
Cage fracture due to poor fitting or in correct usage.

Each time a rolling element passes a defect in the race, an impact is generated.
Each impact a pulse of high frequency vibration.
Spike energy
It is the unit of measure created by IRD Mechanalysis for determining incipient flaws in bearing.
It is a vibration measurement based in high frequency peak acceleration.
Vibration Analysis –gears
Cracked broken teeth generates high amplitude 1*RPM of defective gear shaft.
Time wave form shows pronounced peaks at 1/speed of gear shaft ,i.e every time the broken teeth meshes
,creating an impact.

Causes for Unbalance

Unbalance is generally caused due to :
1.PRODUCTION PROCESS.
2.SERVICE EFFECTS.

PRODUCTION PROCESS
Casting impeller pulley
Fabrication fan.
Forging crank shaft.
Other armature .
Castings, Blow holes or sand traps resulting from casting process. the void represents true unbalance.
Eccentricity:
The geometric center line does not coincide with rotating center line.
Eccentric machining ,eccentric hole, oversize web.
Other Causes:
Motor Unbalanced without key.
Pulley balanced without key. Assembly will result in Unbalance.

BALANCING:

The above causes for unbalance exist in a rotor to some extent .

The vector summation of all these can be considered as concentrated at a spot as Heavy spot.
Balancing therefore is a technique for determining the amount and location of heavy spot and
applying correction.

Benefits of Balancing:
Reduced Vibration
Reduced Wear
Reduced Stress/fatigue
Reduced noise
Increased efficiency
Increased Accuracy.

Why is in-situ balancing needed?

1 .Unbalance introduced when stripped and during Reassembly.
2. Rotors running above critical speed –may need trim.
3 .Dirty Process
4 .Heat Distortion.
5. To compensate for wear.

Conditions for in-Situ Balancing:

1. There must be provision for making weight correction.
2. There must be provision for obtaining vibration, amplitude and phase angle.
3. It must be possible to start and stop the machine for making weight correction.

The vibration problem must be due to unbalance.

Recognizing vibration due to Unbalance
Unbalance will produce vibrations at rotational speed.
Vibration amplitude is directly proportional to Unbalance.
The problems like misalignment, Resonance ,looseness ,Eccentricity distortion, Reciprocating forces, Electrical
problems and Aerodynamic forces cannot be corrected by balancing, and when any of these problems occur then
the attempt of balancing is a time waste process ,first we have to attempt all the problems caused and if not
solved we have to conclude that the problem is due to Unbalance and we have to follow the further steps.

One of the method used in the in-Situ balancing is Three Point Circle method.
01. When the rotor operating at normal speed measure and record original Vibration amplitude as ‘O’.
02. Draw a circle with radius with equal to ‘O’ as shown in the figure .1
03. Stop the rotor and mark three points A,B,C approximately 120 deg apart, these points need not be exactly
120 deg apart but he angles of separation must be same.
04. Select the trial weight and attach at “A” on the rotor.
05. Start the rotor and run it to normal speed and record the new vibration amplitude as “O+T1”.
06 .with point “A” as center draw a circle with radius as “O+T1” as shown in figure.3.
07. Stop the rotor and move the trial weight to position ”B” on the rotor.
08 .Start the rotor and run it to normal speed .Measure and record the new vibration amplitude as “O+T2”.
09. With “B” as center point draw a circle with radius equal to “O+T2” as shown in fig.4
10. Stop the rotor and move the trial weight to position “C”.
10. Start the rotor and record the new vibration amplitude as “O+T3” .
11. With point “C” as the center draw a circle with radius equal to “O+T3”.
12 .The three circles drawn form point A,B,C will intersect at a common point “D” as shown in fig.5
Draw a line from the center of the original circle to point “D” and label the line as “T”.
13. Measure the length of the line “T” using the same scale.
14. Balance Correction weight
CW= TW x (O/T), where CW= Correction weight ,
TW= Trial weight,
O= Original Unbalance vibration reading,
T= The measured Resultant Vector.
Using Protractor measure the angle between line “T” and “OA” as shown in the fig.7
15. The measured angle is the angular location of correct weight located relative to point “A” on the rotor.
16. Stop the rotor and remove the Original trial weight from Point “C”.
17 .Attach the correction weight on the Rotor at the angular position determined from the fig.7,i.e is the angle
between the resultant vector and the point OA.
 Finally this In-Situ correction through balancing solution saved the cost of balancing the rotor in a
balancing Workshop.