Technical Presentation

Mobius Institute

Vibration workshop
Jason Tranter
SIRF 2014

www.mobiusinstitute.com | [email protected]
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SIRF 2014 – Vibration Analysis and Bearing Fault Detection Page 1 of 53

Vibration analysis and

bearing fault detection
The essential information you need to know

Jason Tranter
Managing Director, Mobius Institute
[email protected]
General inquiries: [email protected]
www.mobiusinstitute.com

Australia | USA | Belgium | Costa Rica | Training centers in 50 countries

ISO/IEC 17024 Accredited certification per ISO 18436 parts 1, 2 and 3
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Welcome

 Introduction to machines and vibration

 The vibration waveform and spectrum
 A quick review of:
 Unbalance,
 Misalignment, and
 Looseness
 Detecting rolling element bearing defects
 Spectrum analysis
 High frequency detection techniques
 Using vibration analysis to improve reliability

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Page 2 of 53 SIRF 2014 – Vibration Analysis and Bearing Fault Detection

My history

Australia
1999 Started Mobius Institute
1998
Returned to Australia.
Commenced development of 1997
ExpertALERT for Voyager, DCX 1996
data collector, DCX On-line
1995

USA (Seattle)
1994 DLI became PredictDLI
1993 Later became division
Director of Product Development: of ABB then AzimaDLI
ExpertALERT, data collectors 1992
1991
1990 Sold “ALERT” product line
to DLI Engineering and
1989 moved to USA
Developed vibration monitoring
systems 1988

Australia
1987
1986 Started ARGO: vibration
consulting and product
1985 development
First involved with vibration analysis 1984

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Mobius history

2014
iLearnReliability released
Won Telstra “Regional Business of
2013 First Category IV course
the Year” Finalist in “Export
Training and certification

Business of the Year” MIBoC ISO/IEC 17024 accredited!

2012
Release of iLearnBalancing
MIBoC established – established 2011
for ISO/IEC 17024 accreditation Current Web site went live with
2010 myMobius membership
(ISO 9001 certified)
2009
2008 Export awards 2003, 2006,
2007, 2008, and 2012
2007
2006
Mobius Institute was formed First of 50 Training Partners
with distance learning courses, 2005 established
classroom training and
E-learning with iLearn

2004
certification in 2004
2003
iLearnVibration [Interpreter]
2002 was released
iLearnAlignment was released
2001
2000 iLearnVibration was released
Mobius was born in 1999 1999
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SIRF 2014 – Vibration Analysis and Bearing Fault Detection Page 3 of 53

Let’s get started!

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Your machines are talking to you!

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Page 4 of 53 SIRF 2014 – Vibration Analysis and Bearing Fault Detection

Broad overview
Let’s get started.

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How can we utilize vibration?

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SIRF 2014 – Vibration Analysis and Bearing Fault Detection Page 5 of 53

Broad overview

We are interested in how much vibration exists at different

frequencies, and in some cases, how the machine and
structure moves as a result.

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Vibration fundamentals

Vibration analysis is quite complex!

Before we can look at spectra we need to take a look at the
simple sine wave – the most basic element of vibration.

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Page 6 of 53 SIRF 2014 – Vibration Analysis and Bearing Fault Detection

Vibration frequency
Introducing the spectrum.

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Vibration frequency

Different components within the machine generate

different frequencies: shaft, bearings, gears, vanes and
blades.

Vibration at those frequencies tells us what part of the

machine may be damaged.

It is hard to look at a waveform and relate the vibration to

the machine…

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SIRF 2014 – Vibration Analysis and Bearing Fault Detection Page 7 of 53

The origin of the spectrum and waveform

Here we will see the waveforms and spectrum.

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Spectrum analysis basics

Let’s look at the spectrum a little more closely.

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Multiple sources of vibration

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Motor and fan frequencies

Fan blades

Motor and fan speed

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A little more complicated

(Belt drive halves the speed)

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Motor and fan frequencies

Fan blades
Fan speed

Motor speed

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Page 10 of 53 SIRF 2014 – Vibration Analysis and Bearing Fault Detection

Even more complicated

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Gearbox frequencies

Gearmesh

Output speed
Input speed

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SIRF 2014 – Vibration Analysis and Bearing Fault Detection Page 11 of 53

Is the spectrum always that simple?

Introducing “harmonics” and
“sidebands”

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Harmonics: what happens when the

vibration is not smooth

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Nice, smooth, simple vibration: simple spectrum

Single, dominant source of vibration.

One main peak in the spectrum.

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Complicated vibration: complicated spectrum

More than one source of vibration.

Vibration that is not smooth (non-linear/distorted).

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SIRF 2014 – Vibration Analysis and Bearing Fault Detection Page 13 of 53

Complicated vibration: Impacts: Harmonics

Multiple peaks in the spectrum at the key forcing frequency.

For example:
Running speed: Looseness
Bearing frequency: Wear, spall

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Sidebands: what happens when the

amplitude is not consistent

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Page 14 of 53 SIRF 2014 – Vibration Analysis and Bearing Fault Detection

Complicated vibration: Modulation: Sidebands

A peak at the driving frequency (e.g. gearmesh)

Peaks on either side of that peak, separated by the
modulation frequency (e.g. running speed)

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Complicated vibration: Modulation: Sidebands

Sidebands can take all sorts of forms

Lots of fault conditions generate sidebands:
Bearing, gearbox, motors, pump

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Complicated vibration: Modulation: Sidebands

Sidebands can take all sorts of forms

Lots of fault conditions generate sidebands:
Bearing, gearbox, motors, pump

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Complicated vibration: Modulation: Sidebands

Harmonics (because of the impacts).

Sidebands (because the amplitude rises and falls as the balls
go through the load zone)

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Page 16 of 53 SIRF 2014 – Vibration Analysis and Bearing Fault Detection

Time waveform analysis

Looking at the raw vibration signal.

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Time waveform analysis

 The time waveform is used to generate the spectrum – you don’t

have to collect extra data.
 The waveform shows you what happened from one moment to the
next – the spectrum summarizes everything that happened whilst
the data was recorded.

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SIRF 2014 – Vibration Analysis and Bearing Fault Detection Page 17 of 53

Examples
Let’s look at a few examples where the time waveform has
helped in the diagnostic process

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Damaged inner race of a bearing

Inner race frequency (BPFI)

Running speed (1X)

(Horizontal machine, inner race rotating)

Inner race damage on rolling element bearing

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Page 18 of 53 SIRF 2014 – Vibration Analysis and Bearing Fault Detection

Rotating looseness

Once-per-revolution
impacts

1X harmonics

Rotating looseness

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Cavitation
Non-periodic pulses

Fmax = 1500 Hz (90000 CPM)

Pump cavitation
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SIRF 2014 – Vibration Analysis and Bearing Fault Detection Page 19 of 53

Tooth damage

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Same gearbox without damage

Gear tooth – no damage

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Page 20 of 53 SIRF 2014 – Vibration Analysis and Bearing Fault Detection

Diagnosing fault conditions

How to detect unbalance, misalignment, looseness and
bearing faults

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Spectrum analysis

 The spectrum will change in predictable ways when faults

develop
 May involve 1X, 2X, and/or 3X
 May involve non-synchronous frequencies
 May involve harmonics and sidebands

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SIRF 2014 – Vibration Analysis and Bearing Fault Detection Page 21 of 53

Diagnosing unbalance
A quick introduction to diagnosing mass unbalance.

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Unbalance

 Reducing unbalance is very important:

 Increases stress – reduces life
 Damages the structure
 Damages the bearings
 Amplifies resonance and exacerbates looseness

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Page 22 of 53 SIRF 2014 – Vibration Analysis and Bearing Fault Detection

Causes of unbalance

 Causes of unbalance
 Dirt build-up
 Loss of material
 Wear, cavitation
 Improper manufacture
 Poor castings, incorrect roundness
 Loss of part
 Balance weight, fasteners

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Types of unbalance

 Unbalance can present itself in different ways depending upon

the machine:
 Center hung: Static, couple, and dynamic unbalance
 Overhung machines
 Vertical machines

 For today’s presentation, we will focus on “static” unbalance.

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SIRF 2014 – Vibration Analysis and Bearing Fault Detection Page 23 of 53

Vibration analysis: Static unbalance

 High 1X peak in the spectrum

 Radial vibration (vertical and horizontal)
 Axial with overhung machine
 Phase: 90 between vertical and horizontal
 Phase distinguishes static, couple, and dynamic unbalance

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Case study: ASH HOPPER SLUICE PUMP

 High 1X
 Highest in horizontal

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Case study: ASH HOPPER SLUICE PUMP

 The vibration level at 1X has increased over time.

 That may indicate that there has been a build-up of ash on the
impellor, or there has been uneven corrosion.

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Diagnosing misalignment
A quick introduction to diagnosing misalignment.

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SIRF 2014 – Vibration Analysis and Bearing Fault Detection Page 25 of 53

Misalignment

 Misalignment is very common:

 Most common cause: lack of precision alignment practices
 Other causes:
 Pipe strain
 Foundation problems
 Thermal growth

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Misalignment

 What is misalignment?
 “Shafts are misaligned when their rotational centerlines are
not collinear when the machines are operating under
normal conditions.”

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Page 26 of 53 SIRF 2014 – Vibration Analysis and Bearing Fault Detection

Misalignment

 Unless we take special precautions the

shafts will not be collinear.

 There will be angular and offset

misalignment.

 The misalignment will exist in the

vertical and horizontal direction.

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Parallel (or Offset) misalignment

 High 1X and high 2X radial (often 3X, 4X and 5X are also high)

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SIRF 2014 – Vibration Analysis and Bearing Fault Detection Page 27 of 53

Angular (or gap) misalignment

 High 1X axial vibration

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Case study: Cooling Water Pump #2

 This machine is a 20 HP (15 kW) AC electric motor driving a

centrifugal pump through a flexible coupling. Nominal motor
rotation speed is 3550 RPM. There are 6 vanes on the pump
impeller.

Speed = 3600 CPM

20 HP (15 kW) motor,
Impeller diameter 7.375” (187 mm)
6 pump vanes
Paraflex coupling

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Page 28 of 53 SIRF 2014 – Vibration Analysis and Bearing Fault Detection

Case study: Cooling Water Pump #2

 High 1X and 2X
 Data from pump bearing – vertical axis

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Case study: Cooling Water Pump #2

 Very high 2X in horizontal axis

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SIRF 2014 – Vibration Analysis and Bearing Fault Detection Page 29 of 53

Case study: Cooling Water Pump #2

 1X is high in the axial direction

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Case study: Cooling Water Pump #2

 Misalignment is destructive.
 Look at this data from the motor – there are signs of inner race
bearing wear.

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Page 30 of 53 SIRF 2014 – Vibration Analysis and Bearing Fault Detection

Diagnosing looseness
A quick introduction to diagnosing looseness.

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Looseness

 Looseness is basically caused by:

 Improper fastening techniques
 Improper bearing installation techniques
 Wear within the bearing
 Excessive forces damaging foundations/grouting or
loosening fasteners

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SIRF 2014 – Vibration Analysis and Bearing Fault Detection Page 31 of 53

Looseness

 Unmatched shims / loose bolts / corroded shims

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Looseness

 Missing bolts

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Page 32 of 53 SIRF 2014 – Vibration Analysis and Bearing Fault Detection

Looseness

 Loose hold-down bolts (and damaged seals)

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Looseness

 There are actually three forms of looseness

 Type A: Structural looseness or weakness
 Type B: Cracked structure or pedestal bearing looseness
 Type C: Rotating looseness

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SIRF 2014 – Vibration Analysis and Bearing Fault Detection Page 33 of 53

Structural looseness

 Type A: Structural looseness or weakness

 Due to weakness in base plate, across welds, foundation
problems, and so on
 Often excited by unbalance
 Structure is weak/loose and is allowed to vibrate

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Structural looseness

 Type A: Structural looseness or weakness

 High 1X vibration: Vertical or horizontal
 Phase can be used to diagnose this fault

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Page 34 of 53 SIRF 2014 – Vibration Analysis and Bearing Fault Detection

Case study: ASH HOPPER SLUICE PUMP

 High 1X
 Highest in horizontal

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Pedestal looseness

 Type B: Cracked structure or pedestal bearing looseness

 High 1X and 2X vibration
 Phase erratic

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SIRF 2014 – Vibration Analysis and Bearing Fault Detection Page 35 of 53

Rotating looseness

 Type C: Rotating looseness

 High 1X and harmonics
 Phase erratic

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Diagnosing bearing faults

A quick introduction to diagnosing bearing faults.

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Page 36 of 53 SIRF 2014 – Vibration Analysis and Bearing Fault Detection

Bearing vibration

 One of the keys to a successful vibration program is to detect bearing

defects early.
 We should also do what we can to detect and eliminate the root
causes.
 Fortunately, bearing vibration has unique characteristics.

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Bearing defect fault development

Rolling element bearings give a lot of warning before failing

(unless high speed and high load).

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SIRF 2014 – Vibration Analysis and Bearing Fault Detection Page 37 of 53

Bearing faults: Outer race defect

 Non-synchronous | Harmonics | No sidebands

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Bearing faults: Inner race defect

 Non-synchronous | Harmonics | 1X frequency sidebands

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Bearing faults: Ball or roller defect

 Non-synchronous | Harmonics | Cage frequency sidebands

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Enveloping (also known as

demodulation)
Using acceleration enveloping (also known as demodulation)
to detect faults.

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Vibration analysis: Enveloping

 In the early stage of bearing failure the vibration is unique: Very low
amplitude and very high frequency

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Vibration analysis: Enveloping

 Filter-out the low-frequency, high amplitude vibration.

 “Rectify” the vibration signal
 Using low-pass filter to “envelop” the data
 View as a time waveform or spectrum

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Page 40 of 53 SIRF 2014 – Vibration Analysis and Bearing Fault Detection

Vibration analysis: Enveloping

 The spectrum will change in predictable ways

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Other high frequency bearing defect

detection techniques

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SIRF 2014 – Vibration Analysis and Bearing Fault Detection Page 41 of 53

High frequency detection techniques

 Shock pulse:
 Use a special transducer tuned to approximately 30 kHz
 Trend parameters and spectrum analysis
 Spike Energy
 Was once like shock pulse
 Transducer “resonance” is no longer controlled
 SPM HD
 Improved signal processing for low speed machines
 SWAN
 Stress Wave ANalysis
 PeakVue
 High speed acquisition and “peak detection”

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A few tips
Making sure you collect good data

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Page 42 of 53 SIRF 2014 – Vibration Analysis and Bearing Fault Detection

Make sure you collect good data

 How do you mount your vibration sensor?

 How do you set your Fmax and LOR?
 How do you choose your envelope filter settings?

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How good are your measurements?

 How do you mount your vibration sensors?

 The peak at 1135 Hz is a different amplitude in each case.

Magnetic
Hand-held
Adhesive base. Freq.
probe.
mounting. Freq.1135
Freq.1135Hz
1135Hz
Hz
2.95 0.164
6.34 mm/s rms or 0.142
2.55 0.353 IPS peak

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SIRF 2014 – Vibration Analysis and Bearing Fault Detection Page 43 of 53

How good are your measurements?

 How do you mount your vibration sensors?

 The peak at 1135 Hz is a different amplitude in each case.

Hand-held probe Magnetic base Adhesive

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How good are your measurements?

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How good are your measurements?

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Utilizing vibration analysis to

improve reliability
Does vibration analysis improve reliability?

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Reliability improvement

 Does vibration analysis improve reliability?

 No:
 It finds problems that should not exist
 It reduces maintenance costs and reduces downtime

 Yes:
 When it is used to detect and correct unbalance, misalignment,
looseness, resonance, etc.
 When it is used to check installations, alignment, etc.
 When it is used for acceptance testing

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Why do bearings fail?

 Let’s think about why bearings fail

Bearing failure
Handling &
installation
16%
Fatigue
Contamination 34%
14%

Lubrication
36%

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Page 46 of 53 SIRF 2014 – Vibration Analysis and Bearing Fault Detection

Fatigue: 34%

 Speed effects
bearing life – but
that is not our
biggest concern

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Fatigue: 34%

 Load has a much

greater effect on
bearing life.

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SIRF 2014 – Vibration Analysis and Bearing Fault Detection Page 47 of 53

Fatigue: 34%

 Angular
misalignment
reduces the life of
the bearing based on
the results of this
study.

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Check the repair/replacement

Don’t assume that the work was done correctly

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Page 48 of 53 SIRF 2014 – Vibration Analysis and Bearing Fault Detection

Quality assurance and quality control

 Do you check the condition of the machine when it is returned to

service?
 Is it aligned, balanced, tight?
 Is there resonance?
 Is it lubricated?
 Were the bearings installed correctly?

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Perform acceptance testing

Don’t assume that everything you buy is of the highest
quality.

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Acceptance testing

Two major issues:

What are you purchasing?

What are you receiving?

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Acceptance testing: Purchasing

 What is the charter of your purchasing department?

 Bargain hunters with a short term view
 Quality buyers with a long term view?

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Page 50 of 53 SIRF 2014 – Vibration Analysis and Bearing Fault Detection

Acceptance testing: Purchasing

 What are you buying?

 Counterfeit bearings?
 Lubricants that don’t meet specs?
 Flimsy fans and pumps mounted on bases that resonate?
 Inefficient motors and pumps that are not rated correctly?
 Machinery with poor reliability and maintainability?

 Who does your repair work?

 The lowest cost bidder?
 What specs are given to the balancing company?
 Are motors re-wound correctly?
 What tests are the vibration consultants and oil laboratory
performing?

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Acceptance testing: Incoming testing

 Common assumptions:
 Purchased equipment is in “perfect” condition
 Overhaul/repair work is performed correctly

 Sadly, that is not correct

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SIRF 2014 – Vibration Analysis and Bearing Fault Detection Page 51 of 53

Acceptance testing: Incoming testing

 Don’t assume equipment/lubricants/overhauls will be of high quality,

mandate that it will be!
 Provide detailed testing specifications as part of the purchase
specifications
 Your competitors will get the equipment you reject

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Acceptance testing: Incoming testing

 If the equipment/lubricant/
overhaul does not pass, do not
accept it
 The warranty period should
begin when the tests have been
passed
 Payment can be in stages based
on the tests performed

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Page 52 of 53 SIRF 2014 – Vibration Analysis and Bearing Fault Detection

Acceptance testing: Incoming testing

 The tests will depend upon the items

purchased
 Some tests may be performed at
the supplier’s workshop
 Some tests may be performed at
your site

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Acceptance testing

 The “acceptance testing” specification may include some or all of the

following items:
 Measurement locations
 Type of measurements (spectra, shock pulse, etc.)
 Type of sensors to be used
 Load conditions during the test(s)
 Run-in period before the test is performed
 Qualifications of the person performing the tests
 Amplitude limits that must not be exceeded

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SIRF 2014 – Vibration Analysis and Bearing Fault Detection Page 53 of 53

Acceptance testing

 The greatest challenge is to know what the specifications should say.

 Clear instructions must be provided so that there can be no debate

about whether a machine passes or fails.

 There are basically three approaches you can take:

 ISO Standards
 Guidelines published within the industry
 Industrial experience

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Thank you!
That concludes this workshop.
Jason Tranter
Managing Director, Mobius Institute
[email protected]

General enquiries: [email protected]

www.mobiusinstitute.com

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