UNIVERSITI TEKNOLOGI PETRONAS MBB 3103 VIBRATION LABORATORY MANUAL MACHINERY FAULT SIMULATOR 2 fered - FOR INTERNAL USE ONLY - INSTRUCTION TO STUDENTS 1. Read the Laboratory Manual before the lab session begins. There are 3 exercises in this workbook. Attempt ALL experiments, }. Answer ALL questions in the workbook. . The total maximum duration of the laboratory session is 2 hours. Each group should submit a report in one week. oe Rw NK Plagiarism is strictly prohibited. Any report found improperly referenced and copied from others will not be accepted for assessment. Mechanical Engineering Department Universiti Teknologi PETRONAS4 @ NOISE & VIBRATION LABORATORY yee SAFETY PRECAUTIONS 1 INTRODUCTION Health and Safety at Work Act 1994, its based on the self-regulation concept. It isa legal requirement th © Toensure safety and health of themselves as well as other who may be exposed to risks arising from their ‘work activities. © Through effective and efficient safety management systems suited to the nature of the work activity at the workplace 2. ‘SAFE PRACTICE FOR ENGINEERING TRAINEES You should acquire and practice the safe methods of your chosen skill and by the use of intelligence, initiative and knowledge ensure the safety of the workshop and remove the risk of injury or disablement to yourself and your colleagues. 3, SAFETY AWARNESS Genuine safety comes from following the example set by your instructor and developing safety awareness wt the same as ‘road sense’ when driving. 4, MAJOR POTENTIAL HAZARDS The list below are the major potential hazard in the Material Laboratory 1. Injury through misuse-applies to all equipment. 2. Poisoning from toxic material-Nital, HCI, etc. 3. Injury from electric shock-ll equipment. 4. Injury from heavy equipment-All equipment. 5. Injury from sharp objects or edges-drag, etc 5. GENERAL INSTRUCTIONS The general instructions are given as follows: Never misuses any equipment know the fire exit and locations of safety equipment Avoid overcrowding at one place. Avoid closing to a source o heat/ any high temperature component. Report any accident/ damage to the laboratory staff. Near/ miss accident should also be reported. 6. ‘SPECIAL INSTRUCTIONS Wear suitable clothes/ lab coat and protection equipment, goggles, visor, gloves, ete Do not bring foods/ drinks or eat/ drink into the laboratory ‘Smoking is strictly prohibited Wear shoes. Sandals and slippers are not allowed. Never be playful in the laboratoryVariable Speed Analysis & Reciprocating Mechanism LAB EXERCISES ON SPECTRUM ANALYZER Resonance & Bearing Fautt Studies (Sleeve & Rolling) Cthical Speed Shaft Alignment Motor Current Signature ~ Anolysis 7 Loading Effect Center/Overhung Muttiplane Balancing ‘Bek Drive Issues Foundation Dynamics Gearbox Studies Figure 1: SpectraQuest’s Machinery Fault Simulator (MEFS) 1 OBJECTIVES Baseline Vibration Lear the main components of the Machine Fault Simulator (MFS), Learn how to run the MEFS and how to use the VQpro software, Run the system at selected speed and record baseline data for latter analysis of the faulty signals. Bearing Fault Experiment Study the effect of bearing fault on the vibration response at the bearings Lear how to use vibration analysis tools Resonance Test Study the effect of resonanceI. PROCEDURE A Baseline Vibration Bearing Bearing Loader Right-side Bearing on the MFS Figure 1: Setup for Baseline and Bearing Fault Exercise . Install the two rotors and bearing loaders according to the setup shown in Fig. 2. Arrange the rotor in such a way that only two discs are mounted on the shaft. Install two normal bearings at both left and right side of the machine. Arrange four accelerometers to record the vibration signal at the two bearings. Rum the system at five different speeds provided for the group. Record the data at certain frequencies and resolutions. . Export the recoded data to excel and take a copy for analysis, Analyze the data using root mean square (RMS), Crest Factor and Peak to Peak. SARK AYHE Bearing Fault Experiment - Install the two rotors and bearing loaders according to the setup shown in Fig. 2. 2. Install one faulty bearing at the left-side of the machine and one normal bearing at the right-side of the machine. 3. Mount the four accelerometers at the two bearings. 4. Start the MFS and run it at five different speeds provided for the group. 5, Record the corresponding data. 6. Add unbalanced mass and repeat the experiment. 7. 8 . Export the recoded data to excel and take a copy for analysis. . Analyze the data using root mean square (RMS), Crest Factor and Peak to PeakResonance Test eean Figure 3: Setup for resonance test . Install the resonance kit. .. Mount the four accelerometers at the two bearings, Arrange the rotors at equal distance with each other, Make sure that the connections between the rotors and the shaft are tight enough. }. Start the MFS and gradually increase the speed until vibration starts to increase. Keep increasing the speed until the vibration reaches maximum. Further increasing the speed will be seen accompanied by a decrease in the vibration amplitude. Reduce the speed gradually and make note of the speed at which the vibration amplitude gets maximum, Record the speeds at which the vibration amplitude are maximum, Connect one screw to one rotor to induce unbalanced weight. Repeat the above steps and record the vibration signal. Change the location of the rotors and repeat the test.WL = THEORY ‘The approach used to measuring defects in the time domain is using the RMS, Peak-to-Peak and Crest Factor approach. Description Peak to peak |e As an indication of the amount of lateral movement of the machine. Peak-to-peak = Xmax — Xmin Ris (root mean square) 1 = [LY x Xrms fi yx Crest factor © To give an idea of how much impacting is occurring ina waveform © Signal with more peak will have higher crest factor will have higher crest factor # Formula is given as | max (1X1) = Xrms Soe IV. RESULTS AND DISCUSSION Exercise A & B a) Calculate the value of RM b) Plot the graph = RMS ys Speed of motor Crest Factor vs Speed of motor Crest Factor and Peak to Peak for each recorded data. Peak to peak vs Speed motor ¢) Compare the graph of bearing fauit and unbalance with the baseline data 4) Discuss the effect of motor speed on the recorded baseline data. ©) Discuss the effect of bearing fault and unbalance on the vibration response. Exercise C 8) What are the magnitudes of the critical speeds for each test? 'b) Discuss the effect of change in the rotor location on the critical speed. ©) What is the effect of the unbalanced mass on the resonance? Discuss. 4) Discuss the damaging effect of resonance and suggest remedial actions.