Diagnosis of machinery health by vibration analysis technique

Babla Ghosh Prof. Debabrata Nag

Sr. Divisional Engineer (Mech)
ISO-Level-II certified Vibration Analyst ………………………..
Damodar Valley Corporation (DVC)
Abstract:
Vibration analysis is a powerful tool for health assessment of rotating machines. Worldwide application in the industry
makes it popular & gives recognition as an indispensable technique in recent maintenance strategy. Maintenancephilosophy
in the industry has changed radically over the use of modern Condition Monitoring techniques. Evolving from the base of
maintenance strategy of FM (Failure maintenance) and PM (Preventive maintenance), people attain to SRCM (Streamline
Reliability Centered Maintenance).And it was possible only due to application of CBM (Condition Based
Maintenance).Vibration Analysis technique gives the confidence to identify the root cause of machinery fault. Therefore it is
possible to make proper planning for taking shut down of the equipment with due consideration the health of the machine.
This paper deals with three practical case studies in Thermal Power Plant and demonstrates the way how vibration
analysiscan save themachine.
Keywords:
Vibration Analysis, Signature, Spectrum, Phase, Balancing, FFT, Time Waveform, vibration level.
Introduction Case-1:
Vibration Analysis
Load carrying component of any rotating machines is Ash Slurry Disposal Pump,DSTPS, DVC
its bearing. Any kind of unbalanced force developed Drive Unit: Motor
in the rotor is being experienced by the bearing. So, Speed: 1500 rpm
when a vibration analyst mounts his vibration probe Power: 235 KW
on bearing cap, he should have an autopsy of the
undulation of the machine component. Proper ISO 10816 Standard Class III
functioning of bearings is most important in nuclear machines
power stations, chemical plants, aviation industries
and also process industries. A large survey on faults in
the electric motor was carried out by Electric Power Standard Vibration Level Machine Condition
Research Institute (EPRI) in 1985 and found that 41%
Up to 4.5 mm/sec Normal
of faults related to worn motor bearings. Machine
4-5 to 11.2 mm/sec Marginal
health and performance can be easily identified by Above 11.2 mm/sec Critical
using health monitoring techniques. Many condition
monitoring techniques is available to monitor the Schematic Diagram:
health of rotating machines; these are wear debris
analysis, motor current analysis, noise monitoring,
temperature monitoring, vibration monitoring etc. But
the vibration monitoring is the most useful technique
because it is reliable and very sensitive to fault
severity. The vibration signals gives us information
about the health of bearing. Many researchers have
been worked on vibration signal analysis techniques
and numbers of research papershave been published
by them. Review papers have also been published by
researchers on the same subject. The aim of this study
is to demonstrate the practicality of vibration phase &
signature analysis.
Vibration Readings: A 8.303
H 7.074
Location mm/sec (rms) V
Gear Box-4 5.117
H 0.418 A 7.055
Motor NDE V 0-658 H 6.939
A 0.443
Pump DE V 7.496
H 0.817 A 5.584
Motor DE V 0.550 H 5.654
A 0.559
Pump NDE V 4.227
H 1.306
Fluid Coupling A 4.258
V 1.066
DE
A 1.080
H 1.608 Signature:
Fluid
V 0.883
CouplingNDE
A 1.732
H 5.442
Gear Box-1 V 5.300
A 7.920
H 6.514
Gear Box-2 V 4.258
A 7.943
Gear Box-3 H 3.728
V 4.662
 Empty Chart Empty Chart
ASH SLURRY PUMP-C - GB-4 - Vertical - Vel Spec/Wfm 120000 CPM ASH SLURRY PUMP-C - GB-3 - Axial - Vel Spec/Wfm 120000 CPM
4
O/All 5.177 mm/s RMS 7 O/All 8.303 mm/s RMS
3.5
6
3
5
2.5
4
mm/s RMS

mm/s RMS
1.5 3

1 2

0.5 1

0 0
0 10,000 20,000 30,000 40,000 50,000 60,000 0 20,000 40,000 60,000 80,000 100,000 120,000
CPM
CPM

Empty
ASH SLURRY PUMP-C - GB-4 Chart- Vel Spec/Wfm 120000 CPM
- Vertical Empty Chart
ASH SLURRY PUMP-C - GB-3 - Axial - Vel Spec/Wfm 120000 CPM
O/All 5.204 mm/s RMS
15 20 O/All 8.349 mm/s RMS
True pk-pk 29.51 mm/s
True pk-pk 38.55 mm/s
Crest Factor 2.835
10 Crest Factor 2.309
10
5
mm/s

mm/s
0

-5
-10
-10

-15 -20
0 50 100 150 200 250 300 350
ms 0 50 100 150 200 250 300 350
14-Jul-16 4:06:48 PM O/All 5.204 mm/s RMS <set RPM> ms
14-Jul-16 4:04:48 PM O/All 8.349 mm/s RMS <set RPM>

Empty Chart
ASH SLURRY PUMP-C - PUMP DE - Horizontal - Vel Spec/Wfm 120000 CPM
3 O/All 6.939 mm/s RMS
Empty Chart
ASH SLURRY PUMP-C - GB-4 - Axial - Vel Spec/Wfm 120000 CPM 2.5
O/All 7.055 mm/s RMS
5 2

mm/s RMS
1.5
4

1
3
mm/s RMS

0.5

2
0

1 0 20,000 40,000 60,000 80,000 100,000 120,000

CPM

0 Empty
ASH SLURRY PUMP-C - PUMP DE Chart - Vel Spec/Wfm 120000 CPM
- Horizontal
0 10,000 20,000 30,000 40,000 50,000 60,000 O/All 7.248 mm/s RMS
CPM 20 True pk-pk 51.24 mm/s
Crest Factor 3.535
Empty Chart
ASH SLURRY PUMP-C - GB-4 - Axial - Vel Spec/Wfm 120000 CPM 10
20
O/All 7.246 mm/s RMS
True pk-pk 36.71 mm/s 0
mm/s

Crest Factor 2.533

10
-10

-20
0
mm/s

-30
0 50 100 150 200 250 300 350
-10 ms
14-Jul-16 4:08:08 PM O/All 7.248 mm/s RMS <set RPM>

-20
0 50 100 150 200 250 300 350
ms
14-Jul-16 4:07:09 PM O/All 7.246 mm/s RMS <set RPM>
Observations:

a. Machine rpm frequency ie, 1X component present in

every spectrum, so the problem of high vibration lies
with the machine itself.
Case-2:
b. The maximum overall vibration amplitudes were
Vibration Analysis of TG-DMCW Pump#1C
recorded at all the gear box bearing and pump DE DSTPS, DVC
bearing at Axial and vertical direction. Also axial Drive Unit: Motor
vibration is dominating at most of the location. Motor Speed: 1480 rpm
c. Raised Noise Floor was observed in the spectrum of Coupling Type:Bush Coupling
Pump brg. This is possibly due to nonlinear response
of the loose part to dynamic forces of rotor. Motor Photograph:
d. Impact in time waveform of Pump brg. is observed,
this is possibly due to rattling of loose parts.
e. A series of asynchronous peak was observed.
f. Defects is in low frequency zone & medium
frequency zone.
g. Cross Phase Analysis Done at all possible points
between GB and Pump found phase difference 160-
170 deg between Pump and GB Horizontal.
h. The Pump DE bearing Temperature was 68*C.

Findings:
a. There may be serious brg. Wear.
b. There may be resonance problem having broad base
appearing in humps.
c. There may be misalignment across the coupling of GB
O/P shaft & Pump Shaft
d. There may be GB oil degradation
Elimination: Chronological Vibration Reading:

a. Resonance is often directional, but it is appearing in Eqpt. Location (velocity-mm/sec-rms)

all direction, so may not be resonance 24.03.17 24.04.17 26.04.17 02.05.17
b. Misalignment gives M or W shapes in time wave Motor H 3.14 1.42 3.01 3.46
form, so may not be misalignment NDE V 7.53 1.51
6.68 1.16
A 15.88 2.38 17.5 2.45
Recommendations:
DMC Motor H 5.95 1.21 6.21 3.25
a. Ensure proper rigidity of Gear box. W DE V 9.14 2.36
8.06 0.84
b. Inspect Gear internal parts. Pump-
A 12.34 1.68 14.55 2.06
TG-1C
c. Recommended Lube oil analysis of gear oil s. Pump H Motor 3.16 1.56
2.5
d. Inspect the bearing of Pump DE. NDE Free
V 2.13 1.95 1.35
e. Ensure Precision Alignment Between GB and Pump. Run
A 1.64 1.76 1.37
 Pump H 1.36 1.68 1.19
DE V 1.14 0.74 DMCW PUMP TG-1C - MOTOR NDE - Horizontal - Vel Spec/Wfm 120000 CPM
1.18
O/All 3.648 mm/s RMS
A 1.43 1.15 1.51 3

M
/sR S
1

m
m
0
0 20,000 40,000 60,000 80,000 100,000 120,000
CPM
6/15/2017 9:44:59 AM O/All 3.648 mm/s RMS <set RPM> <add note>

DMCW PUMP TG-1C - MOTOR NDE - Vertical - Vel Spec/Wfm 120000 CPM
3 O/All 3.295 mm/s RMS
DMCW PUMP TG-1C - MOTOR DE - Horizontal - Vel Spec/Wfm 120000 CPM 2.5
5 2
O/All 5.172 mm/s RMS
1.5

S
4

M
/sR
1

m
3

m
0.5
MS

2
/sR

0
m
m

1
0 20,000 40,000 60,000 80,000 100,000 120,000
0
CPM
0 20,000 40,000 60,000 80,000 100,000 120,000 6/15/2017 9:45:20 AM O/All 3.295 mm/s RMS <set RPM> <add note>
CPM
6/15/2017 9:46:22 AM O/All 5.172 mm/s RMS <set RPM> <add note>

DMCW PUMP TG-1C - MOTOR DE - Vertical - Vel Spec/Wfm 120000 CPM DMCW PUMP TG-1C - MOTOR NDE - Axial - Vel Spec/Wfm 120000 CPM
5 O/All 5.463 mm/s RMS O/All 9.813 mm/s RMS
8
4 6

S
3 4

M
/sR
S

m
M

m
/sR

2 2
m
m

1 0
0 20,000 40,000 60,000 80,000 100,000 120,000
0
CPM
0 20,000 40,000 60,000 80,000 100,000 120,000 6/15/2017 9:45:52 AM O/All 9.813 mm/s RMS 1480 RPM <add note>
CPM
6/15/2017 9:46:32 AM O/All 5.463 mm/s RMS <set RPM> <add note>

DMCW PUMP TG-1C - MOTOR DE - Axial - Vel Spec/Wfm 120000 CPM

8 O/All 8.401 mm/s RMS
6

4
DMCW PUMP TG-1C - PUMP NDE - Horizontal - Vel Spec/Wfm 120000 CPM
m M
/sRS

0.8
m

2 O/All 1.37 mm/s RMS

0.6
0
0.4
MS

0 20,000 40,000 60,000 80,000 100,000 120,000

m/sR

CPM 0.2
m

6/15/2017 9:46:42 AM O/All 8.401 mm/s RMS <set RPM> <add note>
0
0 20,000 40,000 60,000 80,000 100,000 120,000
CPM
6/15/2017 9:49:32 AM O/All 1.37 mm/s RMS <set RPM> <add note>

DMCW PUMP TG-1C - PUMP NDE - Vertical - Vel Spec/Wfm 120000 CPM
0.6 O/All 0.8178 mm/s RMS

0.4
m/sRMS

0.2
m

0
0 20,000 40,000 60,000 80,000 100,000 120,000
CPM
6/15/2017 9:49:50 AM O/All 0.8178 mm/s RMS <set RPM> <add note>

DMCW PUMP TG-1C - PUMP NDE - Axial - Vel Spec/Wfm 120000 CPM
0.6
O/All 0.959 mm/s RMS

0.4
/sRMS

0.2
mm

0
0 20,000 40,000 60,000 80,000 100,000 120,000
CPM
6/15/2017 9:50:04 AM O/All 0.959 mm/s RMS <set RPM> <add note>
 DMCW PUMP TG-1C - PUMP DE - Horizontal - Vel Spec/Wfm 120000 CPM
1.6
1.4 O/All 1.958 mm/s RMS Observation & Analysis:
1.2
1 As per the vibration recording data sheet
0.8
attached above, vibration was very high in
MS

0.6
m/sR

0.4
Motor NDE & DE Axial direction. Initially
m

0.2
0
0 20,000 40,000 60,000 80,000 100,000 120,000
bearing defect was suspected but in FFT
CPM Analysis no peaks in high frequency range was
6/15/2017 9:48:47 AM O/All 1.958 mm/s RMS <set RPM> <add note>
found. Therefore we ruled out the possibility of
DMCW PUMP TG-1C - PUMP DE - Vertical - Vel Spec/Wfm 120000 CPM bearing defect.After FFT Analysis we have
1.5 O/All 1.745 mm/s RMS done the Phase analysis. In phase Analysis we
found approx. 180o phase difference at
1
differentpoints of base plate as mentioned in
MS

data sheet below.

/sR

0.5
m
m

0 Phase Measurement:
0 20,000 40,000 60,000 80,000 100,000 120,000
CPM
6/15/2017 9:48:59 AM O/All 1.745 mm/s RMS <set RPM> <add note>

DMCW PUMP TG-1C - PUMP DE - Axial - Vel Spec/Wfm 120000 CPM C MOTOR BASE PLATE A
0.8
O/All 1.112 mm/s RMS
0.6

0.4 Pump Side

m
m M
/sRS

0.2

0
0 20,000 40,000 60,000 80,000 100,000 120,000
D B
CPM
6/15/2017 9:49:12 AM O/All 1.112 mm/s RMS <set RPM> <add note>

Phase Measurement data of Motor Base Plate before

Rectification:
Phase
Locatio Orientatio
DMCW PUMP TG-1C - PUMP DE - Horizontal - Vel Spec/Wfm 120000 CPM Shift
1.6 n n
1.4
1.2
O/All 1.958 mm/s RMS (Deg.)
1
0.8 A-B V-V 10
MS

0.6
C-D V-V 331
m/sR

0.4
m

0.2
0 B-C V-V 157
0 20,000 40,000 60,000
CPM
80,000 100,000 120,000
A-D V-V 192
6/15/2017 9:48:47 AM O/All 1.958 mm/s RMS <set RPM> <add note>
A-C V-V 163
DMCW PUMP TG-1C - PUMP DE - Vertical - Vel Spec/Wfm 120000 CPM B-D V-V 177
1.5 O/All 1.745 mm/s RMS

1
/sRMS

Phase Scanning Throughout the machine:

m

0.5
m

0
0 20,000 40,000 60,000 80,000 100,000 120,000
CPM
6/15/2017 9:48:59 AM O/All 1.745 mm/s RMS <set RPM> <add note>

DMCW PUMP TG-1C - PUMP DE - Axial - Vel Spec/Wfm 120000 CPM

0.8
O/All 1.112 mm/s RMS
0.6

0.4
mm/sRMS

0.2

0
0 20,000 40,000 60,000 80,000 100,000 120,000
CPM
6/15/2017 9:49:12 AM O/All 1.112 mm/s RMS <set RPM> <add note>
 Location Orientation Phase
Shift(Deg)
Motor-NDE H-V 276
Motor- DE H-V 108
Pump-DE H-V 50
Pump-NDE H-V 303
Motor NDE-
H-H 21
Motor DE
Motor NDE-
V-V 183
Motor DE
Pump NDE-
H-H 77
Pump DE
Pump NDE-
V-V 177
Pump DE
Motor DE-
H-H 205
Pump DE
Motor DE-
V-V 157
Pump DE
Motor DE-
A-A 339
Pump DE
Motor NDE T-B(A) 01
Motor NDE L-R(A) 11
Motor DE T-B(A) 02
Motor DE L-R(A) 10
Pump DE T-B(A) 50
Pump DE L-R(A) 53
Pump NDE T-B(A) 316
Recommendation: Pump NDE L-R(A) 46
After phase Analysis it was recommended by Equipment: Clear Water Pump No. 1
CMC for Blue Matching of Motor Base plate. Class II machines
Action Taken: Function of Equipment: To pump clarified
Blue Matching was done by TG Maintenance water to filter water bed and for CW make-up
section along with shaft alignment. Problem: High Vibration in Motor Free Run
Below mentioned are standard vibration levels for
Phase Measurement data of Motor Base Plate after class II machinesas per ISO10816 Standard:
Rectification:
Standard Machine
Location Orientatio Phase Shift (Deg) Vibration Level Condition
n
A-B V-V 326 Up to 2.8
Normal
C-D V-V 90 mm/sec.
B-C V-V 346 2.8 to 7.1
A-D V-V 24 Marginal
mm/sec.
A-C V-V 291
B-D V-V 65 Above7.1
Critical
Final Result: - mm/sec.

After above rectification the vibration comes Technical Specifications:

down to acceptable limit. Final vibration data
Equipment
sheet attached above. Vertical
arrangement
Case-3: Power 37 KW
Vibration Analysis of Clear Water Pump#1 Speed 1470 RPM
CTPS, DVC
Area: Water Treatment Plant Voltage 415 V
 Also Motor bearing spike energy was captured
and was very high.
Motor NDE 6312 (Single-Row Deep Groove
Maintenance Activities: Pump and Motor
Bearing: Ball Bearing) [nos. of balls- 8]
Overhauling done along with Motor bearing
Motor DE 6313(Single-Row Deep Groove replacement.
Bearing: Ball Bearing) [nos. of balls- 8

Motor fan blades 14

Machine Sketch:
Observation:

On 18/01/2017 Vibration readings were taken as follows:

Eqpt Location Mm/sec(rms)

Clear Motor H 10.6
water NDE V 5.2
Pump#1 A 2.5
Motor H 6.9
DE V 4.2
A 0.78
Pump H 2.07
DE V 2.05
A 0.35

Spike energy Reduced to normal value-0.04 gSE.

Clear Water Pump No. 1
Motor trip test was done and no sharp drop in vibration
reading was observed. So cause of vibration is not
electrical side.
Analysis:
a. Overall Vibration Readings, Motor:The maximum
overall vibration amplitude recorded was 10.6
mm/sec in Horizontal direction at Motor NDE
bearing. As per ISO 10816 standards, it is considered
to be “Critical”.
b. Spectrum Analysis:
Clear Water Pump#1

History of equipment:
On 15-12-2016, very high vibration came into
noticed in Clear water Pump. Maximum
vibration was observed in Motor NDE (Hx)
-250 micron (pk –pk displacement) and rms
velocity-15.1 mm/sec.
On 16-12-2016 Motor Free run was done and
vibration was observed high maximum in
Motor NDE (Hx) 213 micron (pk –pk
displacement) and rms velocity-11.7 mm/sec.
 196 12

339
Phase reading was also taken in horizontal direction from
top to bottom and phase was found unstable .

Interpretation:
a. Indicate soft foot.
b. Foundation plate not in a plane.
c. Poor rigidity of the structur
Action:
Foundation plate was removed and sole plate was found
rusted condition.

Sole plate was replaced by new one and proper labeling

of sole plate and foundation plate was done. Blue
matching of the machine foot and foundation plate was
done to ensure base evenness and to root out any base
plate looseness.
Sloe plate Photograph:

The spectrum shows the dominant frequency at 1500

CPM. 102

Interpretation: This indicates looseness

c. Phase Analysis:
At Motor Base and machine foundation. Blue Matching Photograph:
Phase reading at machine foot and foundation was
200
observed as:
7 7
88

7
 Observation:
Phase reading was taken all along the machine from top to
bottom. Phase was stable. It was observed that phase shift
in 90 deg with the movement probe in 90 Deg.
Interpretation:
Vibration is due to machine imbalance.
Post vibration of motor free run after base
correction.
Date: 20/02/2017
Machine balancing was done
Eqpt Location Mm/sec(rms)
Clear Motor H 5.5
water NDE V 4.4
Pump#1 A 2.0
Motor H 3.8
DE V 3.2
A 1.0

Spectrum after base correction:

Vibration reading observed after balancing

Location Mm/sec(rms)
H 1.2
Motor
V 1.3
NDE
A 0.9
 H 1.0
Motor
V 1.0
DE
A 0.94
H 0.7
Pump
V 0.6
DE
A 0.35

Conclusion:
After Base foot correction and then Machine Balancing,
Vibration level reduced to Normal range.

Reference:
1. Machinery Vibration: Dr. D. Nag
2. EPRI TR-107042, March 1998
3. EPRI-1004377,Dec-2003
4. IRD Mechanalysis Vibration hand book