PeakVueTM and

Autocorrelation

By Dr. Jim Robinson

 Vibration
 Macro Vibration
“to move or swing to and fro”
Body moves on macroscopic scale
 Micro Vibration
Material within body moves on microscopic
scale introducing ‘stress waves’ which
propagate away (on surface) at speed of sound in
body.

2
 Sensor Mounting (Portable Data Collection)

2-pole magnet on clean surface

-adequate for most mechanical faults( excluding
fatiguing)
-not reliable for lubrication faults

Flat rare earth magnet on smooth flat surface

-mechanical faults including fatiguing
-lubrication faults

3
 Analysis Procedure: 1 of 5
1. User selects analysis bandwidth (Fmax), #lines.
and high pass filter (Fhp).
-Fmax based on highest fault frequency
-#lines selected to capture 5 or more periods
of lowest fault frequency
-Fhp greater than or equal to Fmax , default to
1000 Hz for machines greater than 600 RPM
and 500 Hz for machines less than 600 RPM

4
 Analysis Procedure: 2 of 5
2. Route signal from accelerometer through the high
pass filter. Convert to digital signal at a sampling
rate of 2.56*40,000 or 102,400 s/s.
3. Decimate digital stream of data by a factor of
40,000/Fmax saving to the PeakVue waveform
data block the absolute peak value over each
decimation step. Continue until PeakVue data
block of length 2.56*#lines is full.

5
 Analysis Procedure: 3 of 5
4. Compute the PeakVue spectra from PeakVue
waveform.
5.Shift PeakVue waveform until average value is
ZERO
6. Compute the PeakVue Autocorrelation
Coefficient data from the shifted PeakVue
waveform. (Use defining equations on next two
slides).

6
 Analysis Procedure: 4 of 5

Auto correlation Function

Represent individual component in time data block of

length N by xi for i=1 to N, then

R j    xi xi  j
N2
2
N i 1
where
j  0,1, N 2
xi  x t  it  , i  1, 2, N 2
xi  j  x t   i  j  t  ,
7
 Analysis Procedure: 5 of 5

Autocorrelation Coefficient Function

R  j 
A j  
R τ 0 
 1.0  A j   1.0

8
 Example: Fmax= 200 Hz, # lines= 400, Fhp=1000 Hz.

Shifted PeakVue waveform

Fmax= 200 Hz Decimate (saving abs peak) by 40,000/200 = 200 until

data block filled (400 Lines or 2.56*400=1024 data points).

9
 PeakVue Spectrum Derived from PeakVue Waveform
(Cage Freq. = 3.43 Hz; BSF = 40.6 Hz)

10
 Autocorrelation Coefficient Function Identifies
Dominant Impact Sources in PeakVue Data

Computed from PV TWF shifted until mean value=zero

Synchronous averaging is vector averaging, autocorrelation is scalar
averaging

11
 Recommended Trend Parameters

Trend the peak g-level (or p-p since all values

positive) in waveform. This value used to assist
in severity assessment. Guidelines presented on
next slide.
Trend the digital overall computed from PeakVue
spectra. Alarm/Alert based on relative to baseline
values.

12
 Guidelines for setting Pk-Pk PeakVue Time Waveform
Alert Alarm Levels for an inner race fault
(Set Fault Alarm = 2 X Alert Alarm)
Recom m ended P-P Tim e Waveform Alert Lim its

10.000

4.743
Acceleration in g's (p-p)

3.000 3.000

1.000
0.577

0.100
0.103
1 10 100 1000 10000
Speed (RPM)

13
 Case Studies
1. Demonstration of ‘paint’ on surface
2. Flat magnet vs 2-pole for Lubrication
3. Bearing Faults
4. Gear Faults
5. Gear Coupling
6. Lubrication Faults
7. Others

14
 Case Study 1: Significant Paint on Surface
WIZ - EMERGENCY DEST.RECIRC.PUMPSC
P966A -M2P Motor Inboard Horz Peakvue
0.8
Route Spectrum
0.7
RMS Acceleration in G-s

21-Feb-05 11:47:28
0.6 Bearing outer race defect (PkVue-HP 1000 Hz)
OVERALL= .9763 A-DG
0.5 RMS = .9719
0.4 LOAD = 100.0
RPM = 1780. (29.67 Hz)
0.3
0.2
0.1 Fault at Alert
0
0 200 400 600 800 1000 Level
Frequency in Hz
7
Route Waveform
6 21-Feb-05 11:47:28
Acceleration in G-s

(PkVue-HP 1000 Hz)

5
RMS = 1.95
4 PK(+) = 6.15
CRESTF= 3.15
3 DCoff = 0.0

0
Freq: 92.19
0 0.4 0.8 1.2 1.6
Ordr: 3.107
Time in Seconds Spec: .594

15
 Case Study 1: Paint removed from Surface

WIZ - EMERGENCY DEST.RECIRC.PUMPSC

P966A -M2P Motor Inboard Horz Peakvue
2.0
Analyze Spectrum
RMS Acceleration in G-s

Bearing outer race defect 21-Feb-05 11:57:53

1.5 (PkVue-HP 1000 Hz)
RMS = 2.32
LOAD = 100.0
1.0 RPM = 1792. (29.86 Hz)

0.5
Fault well
0
0 200 400 600 800 1000
above ‘Fault
18
Frequency in Hz
Level
Analyze Waveform
15 21-Feb-05 11:57:53
Acceleration in G-s

(PkVue-HP 1000 Hz)

12 RMS = 4.40
PK(+) = 17.06
9 CRESTF= 3.87
DCoff = 0.0 After scraping
6 paint off
3

0
Freq: 92.18
0 0.4 0.8 1.2 1.6
Ordr: 3.087
Time in Seconds Spec: 1.508

16
 Lubrication fault measured with 2 pole
magnet and flat magnet
 Case # 2
– Trends of known lubrication fault using a 2 pole
magnet and a flat magnet on a prepared surface

17
 Noise Increase with Additive of
Lubricant
 PeakVue high g-levels correlated with new lubrication
(limestone and graphite additives)
 Prompted extensive study on the correlation of this
lubricant to vibration levels
 Machine chosen for study instrumented by:
High frequency stud mounted 10 mV/g accelerometer
Stud mounted general purpose 100 mV/g accelerometer
Mounting pad/flat magnet general purpose 100 mV/g
accelerometer
2-pole Magnet on rounded surface general purpose 100
mV/g accelerometer
 Data acquired was a) 24 kHz bandwidth acceleration
spectral data and b) 1000 Hz high pass PeakVue data

18
 Stud mounted 10 mV/g high frequency accelerometer
1HDC - #1 622 EXHAUST BLOWER
#1622EB -HF3 #3 HORIZONTAL STUD 621B40

Max Amp
.38

Plot
Scale
RMS Acceleration in G-s

0.20 Post Grease with Additives

12-Aug-02
0 06:13:59

Prior to Grease with Additives

08-Aug-02
08:52:03
0 8000 16000 24000
Frequency in Hz
69Label:
Regular acceleration spectrum
Stud Mtd High Freq Accel

19
 1HDC - #1 622 EXHAUST BLOWER
#1622EB -F3P #3 HORIZONTAL PKVUE CH.1
Post grease with additives

Plot
Span
25
12-Aug-02 06:03
Acceleration in G-s

0
08-Aug-02 08:45
Pre grease with additives

Time: 452.73
0 100 200 300 400 500 600 700 800 Ampl: .347
Time in mSecs
Label: 10 mV/g Stud Mtd PeakVue

70

20
 General purpose 100 mV/g sensor on a) flat rare earth magnet and b) 2-pole
magnet on clean curved surface

1HDC - #1 622 EXHAUST BLOWER

12-Aug-02
TREND DISPLAY OF PEAK TO PEAK

15-Aug-02

22-Aug-02
a)

03-Sep-02

19-Sep-02
13.3 g's---

20.0
Pk-Pk Waveform in G-s

#1622EB -3MP
.0
06-Aug-02
08-Aug-02

Flat Magnet

---1.3 g's

Lube with additives added after 8/8/02 reading

b)
22-Aug-02
15-Aug-02

20.0

19-Sep-02
#1622EB -32P

03-Sep-02
.0
06-Aug-02
08-Aug-02

4 g's---

---1.5 g's 2-pole Magnet

Date: 03-Sep-02
0 10 20 30 40 50 Time: 13:41:58
Days: 05-Aug-02 To 19-Sep-02 Amp2: 9.375

21
 Data from machine needing
lubrication (judged from
waveform—large g-level and
random)

Transducer mounting:
2-Pole Vs Flat Magnet

22
 Transient Waveform
42P - (Ch B)
30.0000 JOB ID: 8M2CAB
08:45:30
17-Mar-04

Channel B - 2 pole magnet on housing

G's

G's: 9.4255
Seco: 20.7419
0.0
0.0 Seconds 70.0000

23
 Transient Waveform
4FM - (Ch A)
30.0000 JOB ID: 8M2CAB
08:45:30
17-Mar-04

Channel A - flat magnet on mounting pad

G's

G's: 25.4218
Seco: 20.3903
0.0
0.0 Seconds 70.0000

24
  Reliable indication of fatiguing and lubrication
faults are achieved by:
– Mounting Pads + Flat Magnet
– Sensor on mounting pads responsive to 20-28 kHz
 Features
– High waveform g-level in PeakVue
– Little or no periodicity (possible cage frequency)

25
 Case 3: Bearing Faults
1. Outer Race

26
 Bearing-Outer Race
 Case Study #3, Outer Race
 BPFO in Pinion Stand Gearbox
– Speed of shaft=360 RPM
– Peak g-level=37 g’s
– Fault=6.3 g’s

27
 Velocity spectral and acceleration waveform data
(Fmax
max
=800 Hz) from the bearing on the input shaft
of the gearbox (Sept 15)

Velocity
1X GMF

2X GMF
BPFO

4.13 g’s

28
 Peakvue spectral and waveform data (Fmaxmax
=1000
Hz) from the bearing on the input shaft of the
gearbox (Sept 15)

PeakVue
BPFO = 64.38 Hz = 10.75 X RPM

BPFO

36.96 g

29
 Peakvue spectral and waveform data (Fmax max
= 1000 Hz)
from the bearing on the input shaft of the gearbox
before and after bearing replacement

BPFO PeakVue Before Bearing Replacement

PeakVue After Bearing Replacement

30
Closeup picture of the outer race of the defective bearing
showing significant spalling over an area of 5 in. x 5 in.

31
 Bearing (Inner Race)
 Case Study #3. Inner Race
– BPFI on bearing on output shaft
– Severity ascertained from trending

32
 Trend (2 years) of the maximum peak amplitude (g’s)
from the Peakvue waveform and a Peakvue
spectrum on May 25

Trend of Peak g-levels

Fault Level
is 2 g’s

BPFI with 1X RPM sidebands

2X BPFI
1X
RPM

33
 Trend (2 years) of the bearing frequency band
from the velocity spectrum and a Velocity
spectrum on May 25

Velocity
2X GMF

No indication of a bearing fault

GMF

34
 PeakVue Trend Before & After Bearing was Replaced
(Trend of Digital Overall)
RFPD - HOT MILL-F5 PINION STAND 200
HMF5PINSTD-P4H BOT BRG OUTPUT SIDE HORIZ.PK-VUE
0.6

05/18/00
Trend Display
of
OVERALL VALUE
Trend of the digital ‘overall’

02/01/00

06/28/00
0.5

Factor of 10 relative to baseline -- Baseline --

Value: .04003
RMS Acceleration in G-s

0.4 Date: 01/07/99

10/19/99
0.3

0.2
03/25/99
11/06/98

08/17/00
0.1

0
Date: 08/17/00
0 100 200 300 400 500 600 700 800
Time: 13:03:27
Days: 07/31/98 To 08/17/00 Ampl: .01550
Label: Trend After Bearing Replaced
53

35
Picture of the defective bearing with a significant inner
race defect identified by Peakvue trends

36
 Bearing Inner Race

Case Study #3
Inner Race on Fan Coupled End

37
 MNG - T2 Nozzle Air Supply Fan
T2 NozFan -F1P FAN COUPLED END BRG HORIZ
1.4
Route Spectrum
1.2 17-Dec-03 10:33:36
RMS Acceleration in G-s

1.0 (PkVue-HP 1000 Hz)

OVERALL= 2.02 A-DG
0.8 Is this looseness? RMS = 2.02
LOAD = 100.0
0.6 RPM = 2595. (43.26 Hz)
0.4
0.2
0
0 4 8 12 16 20 24
Frequency in Orders
12
Route Waveform
17-Dec-03 10:33:36
9 (PkVue-HP 1000 Hz)
Acceleration in G-s

RMS = 3.65
PK(+) = 10.78
6 CRESTF= 2.95
DCoff = 0.0

0
Ordr: 1.000
0 100 200 300 400 500 600 700 800 Freq: 43.26
Time in mSecs Spec: 1.159
55
38
 MNG - T2 Nozzle Air Supply Fan
T2 NozFan -F1P FAN COUPLED END BRG HORIZ
1.4
Route Spectrum
1.2 Pattern close to ‘looseness’ 17-Dec-03 10:33:36
RMS Acceleration in G-s

1.0 (PkVue-HP 1000 Hz)

OVERALL= 2.02 A-DG
0.8 RMS = 2.02
LOAD = 100.0
0.6 RPM = 2595. (43.26 Hz)
0.4
0.2
0
0 4 8 12 16 20 24
Frequency in Orders
12
Route Waveform
17-Dec-03 10:33:36
9 (PkVue-HP 1000 Hz)
Acceleration in G-s

RMS = 3.65
PK(+) = 10.78
6 CRESTF= 2.95
DCoff = 0.0

0
Ordr: .987
0 100 200 300 400 500 600 700 800 Freq: 42.69
Time in mSecs Spec: .910
56

39
 MNG - T2 Nozzle Air Supply Fan
T2 NozFan -F1P FAN COUPLED END BRG HORIZ
1.0
Route ACorr(Wf)
17-Dec-03 10:33:36
(PkVue-HP 1000 Hz)

RMS = .2637
LOAD = 100.0
0.5 RPM = 2595. (43.26 Hz)

PK(+) = .9811
PK(-) = .4204
CRESTF= 3.72
Correlation Factor

-0.5

Not looseness

-1.0
0 3 6 9 12 15 18
Revolution Number
57
40
 MNG - T2 Nozzle Air Supply Fan
T2 NozFan -F1P FAN COUPLED END BRG HORIZ
1.0
Route ACorr(Wf)
17-Dec-03 10:33:36
Dfreq=4.93 orders (PkVue-HP 1000 Hz)

RMS = .2637
LOAD = 100.0
0.5 RPM = 2595. (43.26 Hz)

PK(+) = .9811
PK(-) = .4204
CRESTF= 3.72
Correlation Factor

-0.5
Probable inner race

-1.0
Rev : 6.894
58 4 5 6 7 8 9 10 Ampl: .550
Revolution Number Dtim: .203
Freq: 213.34
41
 Case Study # 3
Cage Defect Frequency

42
 5HDC - #5M3 COMBUSTION AIR BLOWER
#5M3CA -F3H #3 Horizontal Velocity
0.04
Route Spectrum
PK Velocity in In/Sec

17-Nov-04 16:24:01
0.03 OVERALL= .0895 V-DG

1X only in Vel Spectra PK = .0753

LOAD = 100.0
RPM = 1786. (29.77 Hz)
0.02

0.01

0
0 200 400 600 800 1000
Frequency in Hz
1.5
1.2 Route Waveform
17-Nov-04 16:24:01
Acceleration in G -s

0.9 RMS = .3625

0.6 PK(+/-) = 1.33/1.04
CRESTF= 3.67
0.3
0
-0.3
-0.6
-0.9
-1.2
Freq: 29.77
0 50 100 150 200 250 300 350 Ordr: 1.000
Time in mSecs Spec: .02986
Label: test data new blower bad brgs.

60 Velocity data taken on a bearing on a new blower

43
 5HDC - #5M3 COMBUSTION AIR BLOWER
#5M3CA -F3P #3 Horizontal Pkvue
R MS A cceleration in G -s

1.4
Route Spectrum
1.2 17-Nov-04 16:24:01
(PkVue-HP 1000 Hz)
1.0

0.8 Cage defect in PeakVue with high OVERALL= 2.36 A-DG

RMS = 2.35
LOAD = 100.0
0.6

0.4
g-level RPM = 1788. (29.80 Hz)

0.2

0
0 200 400 600 800 1000
Frequency in Hz
20
Route Waveform
17-Nov-04 16:24:01
A cceleration in G -s

15 (PkVue-HP 1000 Hz)

RMS = 5.46
PK(+) = 18.56
10 CRESTF= 3.40
DCoff = .7538

0
Freq: 12.77
0 0.4 0.8 1.2 1.6 2.0 2.4 2.8 3.2 Ordr: .428
Time in Seconds Spec: 1.039
Label: test data new blower bad brgs.

Peakvue data taken at the same time with high amplitude

61 at cage defect frequency

44
 5HDC - #5M3 COMBUSTION AIR BLOWER
#5M3CA -F3P #3 Horizontal Pkvue
1.0
Route ACorr(Wf)
F F F F F F F F F F F F F F F F F F F F F 17-Nov-04 16:24:01
(PkVue-HP 1000 Hz)

Cage frequency RMS = .1433

LOAD = 100.0
0.5 RPM = 1788. (29.80 Hz)

PK(+) = .5762
PK(-) = .2176
C orrelation Factor

CRESTF= 4.02

>FAG 22215EAS
F=FTF -IO: 12.85
0

-0.5 Pattern of cage, but not ‘distinct

-1.0
Time: .706
0 0.4 0.8 1.2 1.6 Ampl: .392
Time in Seconds
Label: test data new blower bad brgs.

Autocorrelated waveform indicating cage defect frequency

62

45
 63

46
47
 5HDC - #5M3 COMBUSTION AIR BLOWER
#5M3CA -F3P #3 Horizontal Pkvue
1.0
Max Amp
1.00
0.8

PeakVue spectra before inner race trued up

0.6
R MS A cceleration in G -s

0.4

0.2

0
17-Nov-04
16:24:01

PeakVue spectra after inner race trued up

13-Jan-05
08:50:22
0 200 400 600 800 1000
Frequency in Hz

Before and after spectrums

48
 5HDC - #5M3 COMBUSTION AIR BLOWER
#5M3CA -F3P #3 Horizontal Pkvue

PeakVue waveform Before

Plot
Span
20
17-Nov-04 16:24
A cceleration in G -s

PeakVue waveform after

0
13-Jan-05 08:50

0 100 200 300 400 500 600 700 800

Time in mSecs

Before and after waveforms

49
 Case Study 4: Gear faults
Cracked teeth
Eccentric gear

50
 Gear Box: Cracked Teeth
 Case Study 4
Cracked Tooth on Precision Tension Bridle Gear
Box

51
 Plan view of precision tension bridle gearbox
(single speed reduction with two output
shafts)

Only had
sensor
Mounted on
IB of GB

52
Velocity spectral and acceleration waveform data
(Fmax
max
= 2000 Hz) from the bearing on the input
shaft of the precision tension bridle gearbox

SM - Precision Tension Bridle

PT BRIDLE -GV3
0.04 ROUTE SPECTRUM
GM 1
14-Apr-97 07:59:17

350.68
PK Velocity in In/Sec

OVERALL= .0812 V-DG

0.03
Broadening around GM2 had been PK = .0808
LOAD = 100.0
RPM = 526.
0.02
GM 2 trending ‘broader’. RPS = 8.77
201.59

0.01

0
0 500 1000 1500 2000
Frequency in Hz
2.0
WAVEFORM DISPLAY
1.5 14-Apr-97 07:59:17
Acceleration in G-s

1.0 RMS = .3687

PK(+) = 1.59
0.5 PK(-) = 1.86
CRESTF= 5.06
0
-0.5
-1.0
-1.5
-2.0
-2.5
Freq: 351.25
0 50 100 150 200 Ordr: 40.07
Time in mSecs Spec: .02589

53
 Peakvue spectral and waveform data (Fmax=200 Hz)
from the bearing on the input shaft of the precision
tension bridle gearbox
SM - Precision Tension Bridle
PT BRIDLE -GV3
5
ANALYZE SPECTRUM
RMS Acceleration in G-s

4 PeakVue 14-Apr-97 08:28:16

(Filtr- HP 500 Hz)
RMS = 6.50

1X and many harmonics of

LOAD = 100.0
3 RPM = 216.
RPS = 3.60
2
output shaft
1

0
0 50 100 150 200
Frequency in Hz
40 WAVEFORM DISPLAY
14-Apr-97 08:28:16
Acceleration in G-s

30 RMS = 7.16
PK(+) = 36.54
PK(-) = 4.82
20 CRESTF= 5.10

10

-10
Freq: 3.625
0 0.5 1.0 1.5 2.0 Ordr: 1.008
Time in Seconds Spec: 3.288

Two distinct impacts per turn on output shaft

54
 Gearbox
 Case Study 4
– Eccentric gear on post rebuild gear box

56
 Signature consistent with eccentric gear

57
 After replacement of defective gear

Eccentric gear replaced

58
 Defective gear placed in separate
gear box

Eccentric gear found earlier placed in

different gear box
59
 Gear Coupling Faults
Case study # 5
Coupling on a continuous caster turning at
0.4 RPM.

60
 Roll Caster Gear Box and Gear Coupler

61
 Roller Caster #2 Gearbox (0.4 RPM)
Fmax
max
= 150 orders (1 Hz)

#2RC - 2 RC Caster main low spd GB

CASLSGB -1-2 Shft03 OB Ver. 1 Hz Pkvu 3200 L
0.032
RMS Acceleration in G-s
Route Spectrum
10-Aug-04 10:28:36
0.024 (PkVue- HP 500 Hz)
OVERALL= .3111 A-DG
RMS = .3098
0.016 LOAD = 100.0
RPM = 0. (.01 Hz)
0.008

0
0 0.2 0.4 0.6 0.8 1.0
Frequency in Hz
4.0
Route Waveform
3.5
10-Aug-04 10:28:36
Acceleration in G-s

3.0 (PkVue- HP 500 Hz)

2.5 RMS = .4012
PK(+) = 3.71
2.0 CRESTF= 9.24
1.5 DCoff = .0101
1.0
0.5
0
0 800 1600 2400 3200
Time in Seconds
Label: 2 Roll caster bottom west chock

62
 Roller Caster #2 Gearbox (0,4 RPM)
Expanded freq and time Scale
#2RC - 2 RC Caster main low spd GB
CASLSGB -1HZ Shft03 OB Ver. Pkvu 1600 L
0.04
Route Spectrum
RMS Acceleration in G-s

10-Aug-04 10:28:36
0.03 (PkVue- HP 500 Hz)
OVERALL= .3893 A-DG
RMS = .2537
0.02 LOAD = 100.0
RPM = 0. (.01 Hz)
0.01

0
0 0.1 0.2 0.3 0.4 0.5 0.6
Frequency in Hz
3.5
Route Waveform
3.0 10-Aug-04 10:28:36
Acceleration in G-s

2.5 (PkVue- HP 500 Hz)

RMS = .4842
2.0 PK(+) = 3.49
CRESTF= 7.13
1.5
DCoff = .0033
1.0
0.5
0
Freq: .00687
0 100 200 300 400 500 600 700 800 900 Ordr: .969
Time in Seconds Spec: .02071
Label: 2 Roll caster top west chock

63
 Autocorrelation of PV TWF
#2RC - 2 RC Caster main low spd GB
CASLSGB -1-2 Shft03 OB Ver. 1 Hz Pkvu 3200 L
1.0
Route ACorr(Wf)
10-Aug-04 10:28:36
(PkVue- HP 500 Hz)

RMS = .0167
LOAD = 100.0
0.5
RPM = 0. (.01 Hz)

PK(+) = .0740
PK(-) = .0978
Correlation Factor

CRESTF= 5.87

-0.5

-1.0
0 400 800 1200 1600
Time in Seconds
Label: 2 Roll caster bottom west chock

64
 Spectra Pre and Post Coupling Lubrication
#2RC - 2 RC Caster main low spd GB
CASLSGB -G7P Ch.4 Shaft 04 Inboard Ver. PK.
0.012
Max Amp
.0116

Pre Coupling Lubrication 0.009

0.006
RMS Acceleration in G-s

0.003

0
13-Jun-03
15:03:06

Post Coupling Lubrication

07-Aug-03
15:18:34
0 5 10 15 20
Frequency in Hz

65
 PV TWF Pre and Post Coupling Lubrication
#2RC - 2 RC Caster main low spd GB
CASLSGB -G7P Ch.4 Shaft 04 Inboard Ver. PK.

Plot
Span Pre Coupling Lubrication
2.0
13-Jun-03 15:03
Acceleration in G-s

0
07-Aug-03 15:18

Post Coupling Lubrication

0 5 10 15 20 25 30 35 40
Time in Seconds

66
 Gear Coupling Faults
Case study # 5
Coupling on drive end of wire turning roll

 Gear coupling cleaned and relubricated during

recent outage
 Found sections of gear coupling lacked sufficient
lubrication

67
 Paper Machine-Wire turning Drive Side
ST03 - Wire Turning Drive Side
Feb 06 DS -WTV Wire Turning Vertical
0.020
Route Spectrum
PK Velocity in In/Sec

24-Feb-06 07:34:11
0.015
Velocity spectral data OVERALL= .0413 V-DG
PK = .0374

0.010 looks normal LOAD = 100.0

RPM = 159. (2.65 Hz)

0.005

0
0 30 60 90 120
Frequency in Hz
1.2
Route Waveform
0.9
24-Feb-06 07:34:11
Acceleration in G-s

0.6 RMS = .2194

0.3 PK(+/-) = 1.06/.8261
CRESTF= 4.83
0
-0.3
-0.6
-0.9
-1.2
Freq: 2.650
0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 Ordr: 1.000
Time in Seconds Spec: .00044

68
 Paper Machine-Wire Turning Drive
Side
ST03 - Wire Turning Drive Side
Feb 06 DS -WTV Wire Turning Vertical
0.06
RMS Acceleration in G-s

Analyze Spectrum
0.05 24-Feb-06 07:35:02
(PkVue- HP 500 Hz)
0.04 G-levels in alert, signature of a RMS = .0918
LOAD = 100.0
0.03 possible coupling problem RPM = 146. (2.43 Hz)
0.02

0.01

0
0 10 20 30 40 50 60
Frequency in Hz
1.8
Analyze Waveform
1.5 24-Feb-06 07:35:02
Acceleration in G-s

Alert=0.75 g's
(PkVue- HP 500 Hz)
1.2 RMS = .1524
PK(+) = 1.60
0.9 CRESTF= 10.48
DCoff = 0.0
0.6

0.3

0
Freq: 2.434
0 1 2 3 4 5 6 7 8 Ordr: 1.001
Time in Seconds Spec: .01627

69
 Paper Machine-Wire Turning Drive
Side
ST03 - Wire Turning Drive Side
Feb 06 DS -WTV Wire Turning Vertical
1.0
Analyze ACorr(Wf)
24-Feb-06 07:35:02
(PkVue- HP 500 Hz)

The two X component not quite at 180 RMS = .1115

LOAD = 100.0
0.5
degrees—evident in following circular RPM = 146. (2.43 Hz)

plot PK(+) = .7329

Correlation Factor

PK(-) = .1273
CRESTF= 6.57

-0.5

-1.0
0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0
Time in Seconds

70
 Paper Machine-Wire Turning Drive
Side
ST03 - Wire Turning Drive Side
Feb 06 DS -WTV Wire Turning Vertical
0 Analyze Waveform
Impacting at 24-Feb-06 07:35:02
(PkVue- HP 500 Hz)
approximately 160
RMS = .1524
degrees apart LOAD = 100.0
RPM = 146.
RPS = 2.43
1.8
PK(+) = 1.60
1.5 CRESTF= 10.48
Acceleration in G-s

DCoff = 0.0
1.2
0.9 270 90
0.6
0.3
0

180

Revolution Number: .0 - 19.4

71
 Paper Machine-Wire Turning Drive
Side
ST03 - Wire Turning Drive Side
Feb 06 DS -WTV Wire Turning Vertical
0.010
RMS Acceleration in G-s

Analyze Spectrum
0.008 24-Feb-06 15:02:09
4X
(PkVue- HP 500 Hz)
RMS = .0197
0.006
LOAD = 100.0
Following lubrication of coupler RPM = 146. (2.43 Hz)
0.004

0.002

0
0 50 100 150 200
Frequency in Hz
0.18
Alert Level=1 g Analyze Waveform
0.15 24-Feb-06 15:02:09
Acceleration in G-s

(PkVue- HP 500 Hz)

0.12 RMS = .0610
PK(+) = .1688
0.09 CRESTF= 2.77
DCoff = 0.0
0.06

0.03

0
Freq: 2.438
0 1 2 3 4 5 6 7 8 Ordr: 1.004
Time in Seconds Spec: .00279

72
 Paper Machine-Wire Coupling Drive
Side
ST03 - Wire Turning Drive Side
Feb 06 DS -WTV Wire Turning Vertical
1.0
Analyze ACorr(Wf)
24-Feb-06 15:02:09
Periodic activity at 4X with dominate at 1X (PkVue- HP 500 Hz)

RMS = .1053
LOAD = 100.0
0.5
RPM = 146. (2.43 Hz)

PK(+) = .4151
Correlation Factor

PK(-) = .2048
CRESTF= 3.94

Following
Lubrication of
-0.5
Coupling

-1.0
0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0
Time in Seconds

73
 Paper Machine-Wire Coupling Drive Side
ST03 - Wire Turning Drive Side
Feb 06 DS -WTV Wire Turning Vertical
0 Analyze Waveform
No preferred position re shaft for impacting 24-Feb-06 15:02:09
(PkVue- HP 500 Hz)

RMS = .0610
LOAD = 100.0
RPM = 146.
RPS = 2.43
0.18
PK(+) = .1688
Acceleration in G-s

0.15 CRESTF= 2.77

DCoff = 0.0
0.12
0.09 270 90
0.06 Following Coupling
0.03 Lubrication
0

180

Revolution Number: .0 - 19.4

74
 Case Study # 6: Lubrication

1. Lubrication Signature-Missing Cage

2. Lubrication

75
 Pulp Mill—Motor Inboard
140 - 3RD STAGE BROWN STOCK WASHER
221-07-02 -MIA MOTOR INBOARD AXIAL
0.06
Route Spectrum
0.05 21-Feb-06 10:49:04
PK Velocity in In/Sec

OVERALL= .0873 V-DG

0.04 PK = .0842
No obvious periodic activity re machine speed LOAD = 100.0
0.03 RPM = 806. (13.43 Hz)
0.02

0.01

0
0 100 200 300 400 500 600 700 800
Frequency in Hz
1.6
Route Waveform
1.2 2.6 g's p-p
21-Feb-06 10:49:04
Acceleration in G-s

0.8 RMS = .3186

0.4 PK(+/-) = 1.39/1.20
CRESTF= 4.36
0.0
-0.4
-0.8
-1.2
-1.6
0 100 200 300 400 500 600
Time in mSecs

Spectral data and g time waveform appear

to be normal
76
 Pulp Mill—Motor Inboard
140 - 3RD STAGE BROWN STOCK WASHER
221-07-02 -MIA MOTOR INBOARD AXIAL
1.0
RMS Acceleration in G-s

Analyze Spectrum
0.8 20-Feb-06 11:59:47
Little Periodic activity (PkVue- HP 500 Hz)
RMS = 3.21
0.6
LOAD = 100.0
RPM = 941. (15.68 Hz)
0.4

0.2 Peak g-levels of

0
24 g’s well above
0 100 200 300 400 500 Fault of 12 g’s
Frequency in Hz
25
Analyze Waveform
Alert=6 g's Lubrication had very little effect on g level 20-Feb-06 11:59:47
Acceleration in G-s

20
(PkVue- HP 500 Hz)
RMS = 7.17
15
PK(+) = 23.48
CRESTF= 3.27
10 DCoff = 0.0

0
Freq: 381.25
0 0.4 0.8 1.2 1.6 2.0 2.4 2.8 3.2 Ordr: 24.31
Time in Seconds Spec: .02942

77
 Pulp Mill—Motor Inboard
140 - 3RD STAGE BROWN STOCK WASHER
221-07-02 -MIA MOTOR INBOARD AXIAL
1.0
Analyze ACorr(Wf)
20-Feb-06 11:59:47
No consistent periodic activity (PkVue- HP 500 Hz)

Lubrication had very little effect on noise level RMS = .0593

LOAD = 100.0
0.5
RPM = 941. (15.68 Hz)

PK(+) = .6267
PK(-) = .1570
Correlation Factor

CRESTF= 10.56

0
Audible monitoring
during lubrication
showed only
-0.5 momentary noise
reduction

-1.0
0 0.4 0.8 1.2 1.6
Time in Seconds

78
 Pulp
Pulp Mill-Motor Inboard
Inboard

NO CAGE

79
 Lubrication
Case study # 6

• Increase in PeakVue max g-level from 2.5 g’s to

13 g’s in approximately one month
• An increase (slight) in oil level in bearing sump
decreased PeakVue g-level from 13 g’s to 1.6
g’s in less than 3 minutes.

80
 Scrubber Fan (overhung)
Below Alert Level
3000 - CL2 SCRUBBER I.D. FAN #1
311-10-21 -FOH FAN OUTBOARD HORIZONTAL
0.08
Expert Spectrum
0.07
RMS Acceleration in G-s

Bearing/Gear Analysis
0.06 19-Apr-06 14:03:12
0.05 (PkVue-HP 2000 Hz)
RMS = .2513
0.04 LOAD = 100.0
0.03 Data Acquired on 4/19/06 @14:03:12 RPM = 1777. (29.62 Hz)
0.02
0.01
0
Data acquired on
0 200 400 600
Frequency in Hz
800 1000 April 19, 2006
2.5
Expert Waveform
2.0 Alert Level=6 g's Bearing/Gear Analysis
Acceleration in G-s

19-Apr-06 14:03:12
(PkVue-HP 2000 Hz)
1.5
RMS = .5512
PK(+) = 2.38
1.0 CRESTF= 4.32
DCoff = 0.0
0.5

0
0 100 200 300 400 500 600 700 800
Time in mSecs
Label: Bearing/Gear Analysis - Peakvue

81
 Scrubber Fan (overhung)
PeakVue Data acquired on 4/19/06 and 5/29/06

3000 - CL2 SCRUBBER I.D. FAN #1

311-10-21 -FOH FAN OUTBOARD HORIZONTAL

PeakVue TWF increased by 500% over 40 day period

Plot
Span
14
19-Apr-06 14:03
A c c e le ra tio n in G -s

0
29-May-06 14:02

0 100 200 300 400

Time in mSecs

82
 Scrubber
Scrubber Fan
Fan (overhung)
(overhung)
3000
3000 Hz Bandwidth accelerometer
accelerometer data
data over
over 40 day period
3000 - CL2 SCRUBBER I.D. FAN #1
311-10-21 -FOH FAN OUTBOARD HORIZONTAL

Plot
Span
2
A c c e le ra tio n in G -s

19-Apr-06 14:03

No increase in 3000 Hz bandwidth acceleration data

-2
29-May-06 14:03

0 20 40 60 80 100 120 140

Time in mSecs

83
 Scrubber Fan (Overhung)
Above
Above Fault
Fault Level
Level on
on 5/29/06
5/29/06

3000 - CL2 SCRUBBER I.D. FAN #1

311-10-21 -FOH FAN OUTBOARD HORIZONTAL
0.32
Analyze Spectrum
0.28
RMS Acceleration in G-s

29-May-06 14:02:36
0.24 (PkVue-HP 1000 Hz)
0.20 Data Acquired on 5/29/06 @ 14:02:36 RMS = 1.81
LOAD = 100.0
0.16 RPM = 1780. (29.67 Hz)
0.12 Limited (if any) periodic activity
0.08
0.04
Data acquired on
0 May 29, 2006 at
0 200 400 600 800 1000 14:02
Frequency in Hz
14
Analyze Waveform
12 Alert Level=6 g's 29-May-06 14:02:36
(PkVue-HP 1000 Hz)
Acceleration in G-s

10
RMS = 4.68
8 PK(+) = 12.84
CRESTF= 2.75
6
DCoff = .1019
4

2
0
0 0.4 0.8 1.2 1.6
Time in Seconds

84
 Scrubber Fan (Overhung)
No Periodicity

3000 - CL2 SCRUBBER I.D. FAN #1

311-10-21 -FOH FAN OUTBOARD HORIZONTAL
1.0
Analyze ACorr(Wf)
29-May-06 14:02:36
(PkVue-HP 1000 Hz)

RMS = .0272
LOAD = 100.0
0.5
RPM = 1780. (29.67 Hz)
High g-level but no periodicity
PK(+) = .3337
PK(-) = .0949
Correlation Factor

CRESTF= 12.29

0
Typical
Autocorrelation for
lubrication
-0.5
problems

-1.0
0 100 200 300 400 500 600 700 800
Time in mSecs

85
 Type Oiler used on Scrubber Fan

86
 Scrubber Fan (Overhung)
Below Alert Level Following Increase in Oil
Level
3000 - CL2 SCRUBBER I.D. FAN #1
311-10-21 -FOH FAN OUTBOARD HORIZONTAL
0.020
Analyze Spectrum
H H H H
RMS Acceleration in G-s

29-May-06 14:05:31
0.015 (PkVue-HP 1000 Hz)
RMS = .1141
Data Acquired on 5/29/06 @ 14:05:31 LOAD = 100.0
0.010 RPM = 1786. (29.77 Hz)
>SKF 22222C
H=BPFO
0.005
Data acquired on May
0 29, 2006 at 14:05
0 200 400 600 800 1000 following ‘lifting’ the
Frequency in Hz
1.8
Oiler bowl
Analyze Waveform
1.5 29-May-06 14:05:31
(PkVue-HP 1000 Hz)
Acceleration in G-s

Alert Level=6 g's

1.2 RMS = .3061
PK(+) = 1.57
0.9 CRESTF= 5.13
DCoff = 0.0
0.6

0.3

0
Freq: 320.00
0 0.4 0.8 1.2 1.6 Ordr: 10.75
Time in Seconds Spec: .00203

87
 Others: Case Study # 7
Outer Race fault on Vacuum Pump
PeakVue data acquired because of loud audible
noise in headphones driven by the sensor
(accelerometer).

88
 Paper Machine-BPFO Fault on IB of Vacuum
Pump
11 - #4 VACUUM PUMP UNIT
4 VAC PUMP-BIH PUMP 10 INBOARD HORZ 616-69-15
0.040
Route Spectrum
D D D D D D D D D D D D
11-Oct-02 16:32:08
PK Velocity in In/Sec

0.032
OVERALL= .0452 V-DG
PK = .0450
0.024
Noisy Signal LOAD = 100.0
RPM = 224. (3.73 Hz)
0.016 >SKF NU244
No obvious BPFO fault D=BPFO
0.008

0 Data acquired on
0 100 200 300 400 500 600 700 800 10/11/02
Frequency in Hz
0.4
Route Waveform
0.3 11-Oct-02 16:32:08
Acceleration in G-s

0.2 RMS = .0877

PK(+/-) = .2953/.2675
0.1 CRESTF= 3.37
0.0
-0.1

-0.2

-0.3
Freq: 66.33
0 200 400 600 800 1000 Ordr: 17.76
Time in mSecs Spec: .00086

89
 Paper Machine-BPFO Fault on IB of
Vacuum Pump
11 - #4 VACUUM PUMP UNIT
4 VAC PUMP-BIH PUMP 10 INBOARD HORZ 616-69-15
RMS Acceleration in G -s

0.18
Analyze Spectrum
0.15 D D D D D D
11-Oct-02 16:32:44
(PkVue-HP 1000 Hz)
0.12 Early stage BPFO fault based on g-level RMS = .4178
LOAD = 100.0
0.09
Action: Monitor more often (watch trend of g level) RPM = 225. (3.76 Hz)
>SKF NU244
0.06
D=BPFO
0.03

0
Data acquired on
0 50 100 150 200
10/11/02. g-level above
Alert Level=2.2 g's
Frequency in Hz Alert but less than Fault
4.0
Analyze Waveform
3.5
Acceleration in G-s

11-Oct-02 16:32:44
3.0 (PkVue-HP 1000 Hz)
2.5 RMS = .7914
PK(+) = 3.56
2.0 CRESTF= 4.50
1.5 DCoff = -.6622
1.0
0.5
0
Freq: 66.31
0 1 2 3 4 5 6 7 8 Ordr: 17.65
Time in Seconds Spec: .00723

90
 Paper Machine-BPFO Fault on IB of
Vacuum Pump
11 - #4 VACUUM PUMP UNIT
4 VAC PUMP-BIH PUMP 10 INBOARD HORZ 616-69-15
RM S Acceleration in G-s

1.0
Analyze Spectrum
D D D D D D
0.8 16-Jun-03 10:08:01
Advanced BPFO fault based on g-level (PkVue- HP 500 Hz)
RMS = 2.35
0.6 Action: Replace Bearing LOAD = 100.0
RPM = 225. (3.75 Hz)
0.4 >SKF NU244
D=BPFO
0.2 Data acquired on
0 6/16/02. Peak g-levels
0 50 100 150 200 of 26 g’s exceeds Fault
28
Fault Level=4.4 g's
Frequency in Hz
of 4.4 g’s
Analyze Waveform
24
A cceleration in G-s

16-Jun-03 10:08:01
20 (PkVue- HP 500 Hz)
RMS = 5.81
16 PK(+) = 26.12
CRESTF= 4.50
12
DCoff = 0.0
8

0
0 1 2 3 4 5 6 7 8
Time in Seconds

91
 Paper Machine-BPFO Fault on IB of
Vacuum Pump
11 - #4 VACUUM PUMP UNIT
4 VAC PUMP-BIH PUMP 10 INBOARD HORZ 616-69-15
1.0
Analyze ACorr(Wf)
Typical outer race pattern 16-Jun-03 10:08:01
(PkVue- HP 500 Hz)
Significant random noise in TWF (Corr Amp=0.2)
RMS = .0762
LOAD = 100.0
0.5
Significant ‘noise’ in TWF RPM = 225. (3.75 Hz)

PK(+) = .3586
C o rre la tio n F a c to r

PK(-) = .1715
CRESTF= 4.71

0
Typical outer race fault
pattern in
Autocorrelation
-0.5
Coefficient data

-1.0
Time: 1.031
0 0.3 0.6 0.9 1.2 1.5 1.8 2.1 Ampl: .211
Time in Seconds

92
 Paper Machine-BPFO Fault on IB of
Vacuum Pump
11 - #4 VACUUM PUMP UNIT
4 VAC PUMP-BIH PUMP 10 INBOARD HORZ 616-69-15
P K V e lo c ity in In /S e c

0.25
Route Spectrum
D D D D D D D D D D D D
0.20 16-Jun-03 10:55:36
OVERALL= .4517 V-DG
PK = .4523
0.15 Defective Outer Race LOAD = 100.0
RPM = 224. (3.74 Hz)
0.10 >SKF NU244
D=BPFO
0.05
Outer race fault
0
obvious
0 100 200 300 400 500 600 700 800
Frequency in Hz
4
A c c e le ra tio n in G -s

Route Waveform
3 16-Jun-03 10:55:36
2 RMS = .9251
PK(+/-) = 2.91/2.40
1 CRESTF= 3.14
0
-1

-2
-3
0 200 400 600 800 1000
Time in mSecs

93
 Paper Machine-BPFO Fault on IB of
Vacuum Pump
11 - #4 VACUUM PUMP UNIT
4 VAC PUMP-BIH PUMP 10 INBOARD HORZ 616-69-15
RMS Acceleration in G-s

0.010
Analyze Spectrum
D D D D D D
0.008 02-Jul-03 12:23:48
Post Bearing Replacement (PkVue- HP 500 Hz)
RMS = .0555
0.006
LOAD = 100.0
RPM = 225. (3.75 Hz)
0.004 >SKF NU244
D=BPFO
0.002

0
0 50 100 150 200
Frequency in Hz
0.7
Analyze Waveform
0.6
Acceleration in G-s

Alert Level=2.2 g's 02-Jul-03 12:23:48

0.5 (PkVue- HP 500 Hz)
RMS = .1394
0.4 PK(+) = .5842
CRESTF= 4.19
0.3
DCoff = 0.0
0.2
0.1
0
0 1 2 3 4 5 6 7 8
Time in Seconds

94
 Paper Machine-BPFO on IB of Vacuum
Pump
11 - #4 VACUUM PUMP UNIT
4 VAC PUMP-BIH PUMP 10 INBOARD HORZ 616-69-15
0.025
Route Spectrum
P K Ve lo city in In /S ec

D D D D D D D D D D D D
0.020 02-Jul-03 12:22:38
OVERALL= .0637 V-DG
PK = .0636
0.015
Post Bearing Replacement LOAD = 100.0
RPM = 224. (3.74 Hz)
0.010 >SKF NU244
D=BPFO
0.005

0
0 100 200 300 400 500 600 700 800
Frequency in Hz
0.8
Route Waveform
A cc e lera tio n in G -s

02-Jul-03 12:22:38
0.4 RMS = .1822
PK(+/-) = .6302/.6561
CRESTF= 3.60
0

-0.4

-0.8
0 200 400 600 800 1000
Time in mSecs

95
 Other: Case # 7 Gear Oil Pump: Steam
Turbine Driven

 F.D. Fan driven by steam turbine through a

reduction gear box
 Oil (for lubrication) supplied by a gear oil pump
(with electric oil pump as a backup) driven
through gears by the steam turbine
 Gear pump was changed on July 20, 2006.
 Prior to changing, the backup oil pump ran
continuously. After replacing the gear oil pump,
the backup oil pump was not used.

96
 Gear Oil Pump for FD Fan
3308 - Secondary F.D. Fan 7TH SOUTH
522-01-08 -POV LUBE OIL PUMP
RM S Acceleration in G -s

0.7
Analyze Spectrum
0.6 11-Jul-06 09:17:30
1X Looseness signature
0.5 (PkVue-HP 2000 Hz)
16X probable oil pump gear mesh RMS = 1.66
0.4 LOAD = 100.0
RPM = 796. (13.27 Hz)
0.3

0.2
0.1

0
0 100 200 300 400 500 600
Frequency in Hz
35
High g-level (31 g's) Analyze Waveform
30
A cceleratio n in G -s

11-Jul-06 09:17:30
25 (PkVue-HP 2000 Hz)
RMS = 2.04
20 PK(+) = 30.96
CRESTF= 15.19
15
DCoff = 0.0
10

0
Freq: 212.27
0 100 200 300 400 500 600 700 800 Ordr: 16.00
Time in mSecs Spec: .295

97
 Circular plot of PeakVue data

3308 - Secondary F.D. Fan 7TH SOUTH

522-01-08 -POV LUBE OIL PUMP
0 Analyze Waveform
11-Jul-06 09:17:30
(PkVue-HP 2000 Hz)

RMS = 2.04
LOAD = 100.0

Dphase of 24o
RPM = 796.
RPS = 13.27
35
PK(+) = 30.96 corresponds to 15 teeth
Acceleration in G-s

30 CRESTF= 15.19
25 DCoff = 0.0
20
270 90
15
10 Impacts are very ‘crisp’
5
0
Time in mSecs

Phas: 243.32
Time: 653.90
Rev : 8.676
Ampl: 29.74

Dpha: 24.10
180 Drev: .06693
Ordr: 14.94
Revolution Number: .0 - 10.6 Freq: 198.23

98
 Gear Oil Pump (new pump)
3308 - Secondary F.D. Fan 7TH SOUTH
522-01-08 -POV LUBE OIL PUMP
RM S A cceleratio n in G -s

0.5
Oil Pump Replaced on July 20, 2006 Expert Spectrum
0.4 Bearing/Gear Analysis
16X is probable oil pump GM 25-Jul-06 08:47:56
(PkVue-HP 1000 Hz)
0.3
RMS = .9781
1X LOAD = 100.0
0.2 RPM = 848. (14.13 Hz)

0.1

0
0 200 400 600 800 1000
Frequency in Hz
6
Expert Waveform
A cceleratio n in G -s

5 Bearing/Gear Analysis
25-Jul-06 08:47:56
4 (PkVue-HP 1000 Hz)
RMS = 2.20
3 PK(+) = 5.50
CRESTF= 2.50
2
DCoff = 0.0
1

0
Freq: 226.06
0 100 200 300 400 500 600 700 800 Ordr: 16.00
Time in mSecs Spec: .335
Label: Bearing/Gear Analysis - Peakvue

99