LEVEL 2 – LESSON 3

MONITORING MACHINERY VIBRATION USING DYNAMIC

AND PROCESS CONTROL SIGNALS
 INTRODUCTION
Welcome to Level 2, Lesson 3 of CTC’s free online vibration analysis training. We’re glad
you have taken the time to view this self-paced lesson on monitoring machinery vibration
using dynamic and process control signals. We hope you enjoy the training and will
continue to build your vibration analysis knowledge as you progress through Level 2.

‘Monitoring Machinery Vibration Using Dynamic and Process Control Signals’ is created and presented by CTC for
complimentary educational use only. This training presentation may not be edited or used for any other purposes without
express written consent from CTC.

2 | LEVEL 2, LESSON 3 - MONITORING MACHINERY VIBRATION USING DYNAMIC AND PROCESS CONTROL SIGNALS
 OBJECTIVES
After completing this training module you will understand:

❑ The difference between a dynamic signal and a process control signal

❑ The strengths and limitations of each type of signal

❑ How to use dynamic signal and process control signal together in some
instances to offer an optimal level of protection for critical machinery

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 TRADITIONAL VIBRATION MONITORING
Traditionally, industry has been monitoring machinery vibration with various specialized vibration analyzers.
The most widely used systems are designed to trend the vibration levels of various critical capital equipment.
Typically, a vibration sensor sends a dynamic signal (a mV output of the time waveform) to the analyzer. The
analyzer can then convert the time waveform into an FFT which displays the amplitudes of the individual
frequencies which make up the complex time waveform.

A trained analyst can study the FFT and time waveform trends to determine what types of problems a piece of
machinery might be experiencing, and further identify the root cause of such problems.

Vibration analysis systems typically take the form of online monitoring systems which continually poll a series
of measurement points; or portable data collectors which can be used for periodic measurements. Either type
of equipment can be very effective for analysts to trend vibration levels, set alarms and monitor a wide range
of faults on a wide range of applications.

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 VIBRATION MONITORING –
TRADITIONAL METHODS FOR VIBRATION ALARMS
Several methods have been used to establish vibration alarms. At their most basic, all methods attempt to
establish a baseline at which a piece of machinery operates in a normal or healthy state. Analysts will typically
set two alarm levels (although some utilize more) at some level of increased vibration over this normal state.
The alarms are designed to alert an analyst or end user to a potential problem with the machinery.

The first alarm, many times referred to as the “yellow alarm,” would warn analysts or end users that vibration
levels have increased and an in-depth analysis of machinery is in order. At higher vibration levels, typically a
“red alarm” is triggered indicating that catastrophic failure is a serious near term threat. Sometimes red alarm
levels can trigger either an automatic or manual shutdown of the machinery.

Some examples of typical alarm methods are:

❑ Trending – overall or peak values, or the crest factor
❑ Time Waveform Values – peak, or peak to peak
❑ FFT Monitoring – masking, banding, or enveloping

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 VIBRATION MONITORING – TRENDING
Overall Value, Peak Value, Crest Factor

In this trend display, the overall value has been recorded over a period of 5 years. Warning, alert, and fault alarms were set,
but never exceeded. You could have also trended the peak value or crest factor.

Trending alarms based on overall, peak, or crest factor are very useful for alarming for a general vibration level. It is
important to keep in mind that an individual fault frequency could be overshadowed by the increase or decrease in
amplitudes of other fault frequencies; or it could be ignored or disproportionately weighted relative to other frequencies
contributing to the trend value.

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 VIBRATION MONITORING –
TIME WAVEFORM
Peak, or Peak to Peak Values

In this time waveform, the Peak, or Peak to Peak values of the time waveform can be alarmed. This is a much more
instantaneous type of alarm, and the impacts in the time waveform are exceeding the “alert” and “fault” limits.

Again, a specific fault frequency which could indicate a bearing fault (for example) could be overshadowed by lower
frequency, higher amplitude vibrations. This tends to be a good alarm method for catching lower frequency transients, and
impacting.

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 VIBRATION MONITORING – FFT
Masking / Banding / Enveloping
In this FFT, a process of Masking, Banding, or Enveloping
specific frequency regions is being used.

This method works very well when you want to have

different alarm levels at different frequency ranges so that
you can monitor for specific faults.

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 TRADITIONAL VIBRATION MONITORING

ONLINE PORTABLE
MONITORING DATA
COLLECTION

Historically, these monitoring methods have required specialized vibration instrumentation.

However, in today’s environment of Process Control, 4-20 mA current loops can be used with existing PLCs or DCS
systems to generate vibration alarms, primarily using systems which many industrial plants already have on site.

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 TRADITIONAL CONCEPTS –
ADDED VALUE OF PROCESS CONTROL
A process control signal (such as 4-20 mA) can assist traditional vibration analysis in protecting:
❑ Critical applications
❑ Applications which can fail quickly
❑ Applications which can fail “dramatically”
❑ Applications which are remote, or where no operators can monitor the machinery

The PLC or DCS can constantly monitor for catastrophic failure and alarm analysts for potential
problems. This allows analysts to spend more time on analysis and less time putting out fires, or
worrying about a catastrophic failure due to operator error or environmental issues between route
measurements.

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 PROCESS CONTROL –
FOR PLC OR DCS SYSTEMS
The 4-20 mA signal can be provided to the
PLC or DCS by any of the following
methods:
PLC /
❑ 4-20 mA loop power sensor
DCS
❑ Dual output loop power sensor
that provides 4-20 mA and a
dynamic vibration signal

❑ Transmitter which converts or

“conditions” a standard mV
(dynamic) signal to a mA signal

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 TRADITIONAL CONCEPTS –
HOW DOES IT WORK?
The loop power (4-20 mA) sensor or transmitter generates a
current signal which is scaled to the ”maximum load” (the highest
vibration level the user would plan to alarm for) and is represented
by a 20 mA output. An output of 4 mA represents “no load” (no
vibration).

It is important to understand that the 4-20 mA signal output is

proportional to the overall amplitude generated within a defined
frequency band.

Therefore, the signal does not include data from frequencies

outside the frequency band, and includes all vibration (critical
faults and non-critical) within that band.

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 PROCESS CONTROL – PROCESS SCALING
Scaling is an important factor to consider when specifying a loop power sensor. The scale (or “measurement range”) you choose
should position the vibration levels at ”normal” or “healthy” conditions at roughly 8 to 10 mA of output. This will allow you to
establish alarm limits (for example) at 12 to 16 mA and shutdown limits at 18 to 20 mA. It is important that you remember that
the overall amplitude will be based on the frequency band you have selected for your sensor or transmitter.

See the Tech Resources section of our site at www.ctconline.com for a worksheet to assist with setting your scale measurement
range. The chart below shows the scaled output for a 0 to 2 g or 0 to 2 IPS (50.8 mm/s) scale.

GGs or IPS
0.00 0.25 0.50 0.75 1.00 1.25 1.50 1.75 2.00
(Input)
mm/s
0.00 6.4 12.7 19.1 25.4 31.7 38.1 44.4 50.8
(Input)
mA Output 4 6 8 6 12 14 16 18 20

NORMAL ALARM SHUT DOWN

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 PROCESS CONTROL – PROCESS SCALING
In some cases a broader than normal scale may be desired when a significant increase in vibration above normal can be tolerated
before alarm and shutdown would be required.

For example, your application might operate normally at 0.75 IPS and varying loads might make higher overall levels a normal
occurrence that would not merit an alarm. Instead, alarms and shutdown might not be desired until 4.5 IPS.

NORMAL SHUTDOWN
= 0.75 IPS = 4.50 IPS
= 6.40 mA = 18.40 mA

IPS (Input) 0.00 0.63 1.25 1.88 2.50 3.13 3.75 4.38 5.00

mA Output 4 6 8 10 12 14 16 18 20

NORMAL ALARM SHUTDOWN

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 PROCESS CONTROL –
LOOP POWER SENSOR: 4-20 mA
Loop power sensors are normally available in acceleration or velocity output. Acceleration output
will give the higher frequencies more proportional value in the overall amplitude relative to a
comparably specified velocity output sensor.

The acceleration or velocity units can be expressed as Peak or RMS values. Generally speaking,
Peak will provide more information about transient variations, while RMS (which essentially
averages the peaks) will give less attention to transients.

The frequency ranges for loop power sensors are generally available in two fixed bands, such as:
❑ 10 – 1000 Hz (600 – 60,000 CPM)
❑ 3 – 2500 Hz (180 – 150,000 CPM)

Loop power sensors are great for trending and alarming the overall vibration. Just remember,
that since there is no dynamic output from this sensor, there is also no time waveform or FFT, and
therefor is not intended for diagnosing what the alarm might be caused by.

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 PROCESS CONTROL – VIBRATION DATA
This is a 27 minute trend of process
vibration data from a 600 HP Boiler Feed
Pump.

Initially, it looks as if the power failed on all

four of the vibration sensors, creating the
zero output in the center of the display.

❑ How can this be analyzed?

❑ What do you think we should start

looking for as a cause for the loss
of data?

❑ Could this be a powering issue

with our PLC or sensors?

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 PROCESS CONTROL –
VIBRATION DATA WITH MOTOR CURRENT
Let’s re-display the data in a 100 second
interval and add the motor current to the
display.

The motor current also went to zero!

With the addition of other process control

data, we can see that the motor, not the
sensors, was accidently shut off for 45
seconds, and then turned back on. This could
be a topic for “coaching” the end-user, rather
than searching for power issues on the
vibration sensors.

This is a good example of process control data

can help to paint a fuller picture.

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 BLENDED APPROACH –
BEST OF BOTH WORLDS
Dual output sensors and signal conditioners (vibration transmitters) provide a 4-20 mA output and a dynamic signal output. By
utilizing both signals, companies have a solution that gives the best of both worlds:

❑ Continuous monitoring through the PLC or DCS system

❑ Alarming for catastrophic failure through the PLC or DCS system

❑ Diagnostic analysis and trending for specific fault frequencies via a dynamic signal analyzer

❑ Convenient access to all data via permanently mounted sensors which speeds route collection, and
increases the safety of technicians and analysts

❑ Better use of analysts’ time since the analyst can spend less time trending perfectly healthy
equipment and more time analyzing data

❑ Team approach to protection and monitoring brings additional resources to protecting machinery
and plant health

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 BLENDED APPROACH –
DUAL OUTPUT SENSOR

Dual output loop power sensors are a three-wire system that has a primary
4-20 mA output, and a secondary dynamic output.

The 4-20 mA current loop provides the power source and continuous
monitoring output to the PLC or DCS systems.

The secondary voltage output is available in 100 mV/g or 100 mV/in/sec for
dynamic analysis.

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 BLENDED APPROACH –
DYNAMIC SENSOR AND TRANSMITTER
The dynamic signal from a permanently mounted vibration sensor can also be converted to a
process control signal by a vibration transmitter (or signal conditioner).

The transmitter receives a mV signal form the sensor, then filters and scales the signal to a 4-20
mA output. The 4-20 mA signal can then be passed to a PLC or DCS where it can be monitored
with other process control data.

Transmitter systems also allow access to the dynamic signal so that analysts can trend specific
fault frequencies, or diagnose the cause of alarms. Most units offer a buffered output via a BNC
on the face of the transmitter, as well as a pass-through via screw terminals so analysts can run
the signal to a traditional switchbox.

The larger size of the transmitter allows manufacturers to offer greater flexibility for filter options
than standard loop power sensors. This ability for analysts to choose from a menu of high pass
and low pass filters provides the opportunity to target alarms more accurately around a fault,
rather than relying on less specific overall values.

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 BLENDED APPROACH –
DYNAMIC SENSOR AND TRANSMITTER
Standard sensors and vibration transmitters can also be configured with a
local monitoring system to offer several options which are valuable in a
variety of applications, making them an extremely versatile tool for
vibration analysts and process control engineers. These systems can
include:

❑ Relays - make it possible to shut down machinery in the event that

vibration levels exceed a user-defined level

❑ Digital displays of vibration levels in the scaled or actual value

❑ Visual or auditory alarm options such as lights or sirens

❑ Retransmission of a process control signal to a PLC or DCS

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 BLENDED APPROACH –
COOLING TOWER APPLICATION
A good example of protecting equipment or processes using diagnostic and process control signals is a cooling tower application
where the gearbox has been the primary source of problems:
❑ Dual output sensors (red) – on the input and output shafts of the gearbox
❑ mV/g sensors (blue) on all bearings
This allows analysts to trend for bearing faults and alarm for imbalance or gear noise.

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 PROCESS CONTROL – INTEGRATION
DUAL OUTPUT LOOP POWER DYNAMIC
SENSORS VIBRATION
- OR -
SENSORS AND TRANSMITTERS

PROCESS
CONTROL

Remember, integrating dynamic vibration with process control can make a very successful program for monitoring your
machines!

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 SUMMARY
Thank you for taking the time to review this training lesson. We hope that you learned
something that will help you to collect more accurate and quicker data, to allow you to
make better ”calls.”

CTC prides itself on the industry’s best customer service and technical support.
Did you know that CTC employs several Vibration Institute Certified Category 2 and
Category 3 Analysts, and one Category 4 Analyst who trains for the Vibration Institute? It is
all part of our commitment to providing the industry’s best service and support.

For more technical information, additional white papers, and training materials, we invite
you to visit our website at www.ctconline.com.

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 SUMMARY
CTC offers a full range of vibration analysis hardware and process and protection instruments for
industrial use. Our customers choose us time and time again based on:

❑ Superior durability
❑ Accuracy and performance
❑ Quick service (shipping most orders in 3 days)
❑ Knowledgeable support staff
❑ Industry’s only UNCONDITIONAL LIFETIME WARRANTY
on all CTC Line products

CONTACT US AT [email protected] | WWW.CTCONLINE.COM

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