Mikhail Tsypkin
Vibration Specialty Corporation (VSC)
Electric Machines Fault Detection and Diagnosis
Using Vibration Analysis
ABSTRACT
This presentation shows how electrical machinery
operating on ships is often subjected to excessive
vibration due to electrical/mechanical defects in the
electromagnetic machinery system (internal faults) and
distortions in the ship‟s power line (external faults)
which degrades the machinery. The information is based
on the author‟s many years of experience in the field of
rotating machinery vibration diagnostics, including
electrical machines operating in a Maritime Electrical
System. A short theoretical analysis of electromagnetic
excitation forces based on classical electric machinery
theory is included to exemplify how the internal and
external electrical faults create parasitic radial forces
(rotating waves) and tangential forces (pulsating torques)
inside the electric machines, which deteriorates
equipment health.
These faults are illustrated in numerous case histories of
electromagnetic problems from different industries,
which result in machinery vibration that is significantly
above acceptable standards. Among them are: voltage
(current) unbalance, voltage waveform distortion, faulty
control of Variable Frequency Drives (VFD), motor
eccentric air gap, induction motor winding (stator and
rotor) damage, DC motor power supply quality, and
combinations of mechanical and electrical problems.
INTRODUCTION
Condition monitoring and fault diagnosis of different
kinds of machines, including electrical machinery, have
received considerable attention in the last 50 years [1] –
[5]. Hundreds of publications regarding electrical
machinery condition monitoring have been presented
around the world in the last few decades. Condition
monitoring of electrical machinery is a high-priority task
due to the prevalent and continually extended use of
different types of electric machinery (especially motors)
around the world. The aim of this presentation is to
utilize the findings of many years‟ experience in the field
of vibration diagnostics on electrical machines from
different industries as a guideline for how to eliminate
any excessive vibration on shipboard machinery.
Vibration analysis is one of the oldest and the most
successful techniques used for condition monitoring of
rotating machines. In combination with other non-
invasive techniques, it is used in all types of industry.
Practical experience suggests that combining these
techniques will provide greater success in wider
industrial use for electrical machines in the near future.
Machine condition monitoring and fault diagnostics may
be defined as the field of technical activity in which
selected physical parameters, associated with machinery
operation, are observed for the purpose of determining
machinery integrity [3]. Vibration analysis of electrical
machinery is comprised of two types of information: 1)
vibration condition, which is usually evaluated with
regard to special standards or specifications; and 2) data
analysis, which allows for diagnosing of mechanical and
electromagnetic problems in machinery, but these are not
always related to excessive machine vibration. In the
process of vibration analysis, the first of these tasks is
called fault detection and the second one is fault
diagnosis. Fault detection is when a measurement
parameter exceeds a normal operating range. Fault
diagnosis is often associated with condition monitoring,
and focuses on specific changes and symptoms in order
to determine a cause, severity, and corrective action [3].
Many powerful signal processing techniques can be
applied to vibration signals for the purpose of extracting
even very weak fault indications from noise and other
masking signals [4].
ELECTRIC MACHINES VIBRATION
OF ELECTROMAGNETIC ORIGIN
The machinery vibration is always a compound of
forcing function effects (the source) and transfer
function effects (the structural transmission path). There
are two major types of vibration sources in electrical
machinery: mechanical – typical of all rotating machines
and electromagnetic – specific to electrical machinery.
Complete information about mechanical sources of the
vibration in rotating machines may be found in [6]–[9].
Electromagnetic vibration in the electrical machines is a
result of effects of the electromagnetic forcing functions
onto the machinery rotor and stator.
There are two major sources of electromagnetic
vibration in the electrical machinery: radial
electromagnetic forces and tangential electromagnetic
forces. A well designed, normally operating machine
does not have a significant amount of variable
components of electromagnetic forces. However, due to
internal faults or external issues, such as low power
supply quality and type of load, electromagnetic
vibration may create serious problems to a normal
machine‟s operation.
A classical theory of electromagnetic vibration
mathematically describes radial electromagnetic forces
as a force-wave expression [10], [11]:
p( ,t) = P(r, ) cos(r - t - p) (1)
where P(r, ) - The force-wave amplitude;
r - The force-wave order (mode);
- The force-wave angular frequency;
p - The phase angle;
- An angular coordinate;
t - Time.
The force-wave is defined by the amplitude, frequency
and order (mode). The order of the force-wave is a
number of full waves distributed along the stator core
circumference. Stator core natural frequencies depend
on the order of the force-wave.
Tangential electromagnetic forces may create significant
torque pulsation in all types of electrical machines under
certain conditions. The periodic torque component is
superimposed on the constant torque component and
causes torque pulsation. In turn, torque pulsation results
in undesirable speed pulsation, noise, and vibration.
A harmonic (periodic) component of electromagnetic
torque is defined as:
T(t) = T( ) cos( t - ) (2)
where T( ) - The torque component amplitude;
- The angular frequency;
- The phase angle.
References [12] – [17] give a detailed theoretical
analysis of vibration in electric machines operating with
torque pulsation.
CASE HISTORIES
Electric machinery vibration is a result of a unit structure
excitation under the action of a forcing function of either
mechanical or electromagnetic origin. All discrepancies
in the machine‟s operation are reflected in the vibration
signal recorded on the electric machine during its normal
operation. Vibration analysis extracts specific
information from the data that precisely identifies
mechanical problems, such as: imbalance, misalignment,
mechanical looseness, bearing condition, foundation
problems, resonances, etc. Electric machine vibration
data also contain substantial analytical information about
external electrical problems: voltage distortions in the
power line, current/voltage imbalance, etc. as well as
information about internal machinery electrical issues,
such as: stator and rotor winding and core condition and
air gap eccentricity. All figures (spectra) in this section
have their axis labels identified as follows: the horizontal
axis shows frequency in Hertz (Hz) or cycles per minute
(cpm). The vertical axis in the regular spectra displays
peak vibration amplitude (velocity) in inches per second
(ips), except in Case History #1.
Case History #1
This was a 500-kiloWatt (kW), 4-pole Marine
Synchronous Generator with an operating speed of 1500
revolutions per minute (rpm) and an output voltage
frequency of 50 Hz. The Generator was tested during the
operation at linear and non-linear load. Non-linear load
(for example, a rectifier) usually draws non-sinusoidal
current and introduces distortion to the voltage wave
from the source (Synchronous Generator). This is called
harmonic distortion. In this case, the most pronounced in
the Generator current and voltage were 5th, 7th, 11th and
13th harmonics of main voltage wave (50 Hz, line
frequency). One of the substantial side effects of
voltage/current distortion includes a harmonic torque
component, which are is superimposed on the constant
torque component and causes torque pulsation. Torque
pulsation results in speed pulsation and an excessive
amount of machinery vibration.
Spectra presented in this case history have the horizontal
axis showing frequency in Hz and the vertical axis
shows vibration amplitudes in decibels (dB) –
acceleration.
The vibration spectrum measured on the Generator while
operating under a linear (normal) load (Fig. 1) showed
low and acceptable vibration levels. A spectrum
measured on the Generator during operation under a
non-linear load with a high extent of voltage/current
distortion (Fig. 2) contains peaks at 300 Hz (6X line
frequency) and 600 Hz (12X line frequency). The
vibration level at 300 Hz, recorded on the Generator
during the operation under non-linear load, had increased
more than 30 times (30 dB) in comparison with the
Generator operation under the normal load condition.
Figure 1. A vibration spectrum recorded on the
Synchronous Generator during operation under
linear load.
Figure 2. A vibration spectrum recorded on the
Synchronous Generator, during operation under
non-linear load.
Case History #2
Data was recorded on the number of air handler units
operating in the mechanical room of a university‟s
scientific building. Vibration data was indicating a
power line voltage distortion due to operation of an
unknown non-linear load. The power line voltage
frequency in the mechanical room was 60 Hz.
The highest vibration peak amplitude of 0.85 ips at 360
Hz (6X line frequency) was found on the 60-horsepower
(HP) 4-pole induction motor outboard bearing in the
axial direction (Fig. 3). This peak vibration amplitude
was significantly above acceptable vibration levels. Data
recorded on the inboard motor bearing showed only 0.10
ips at 360 Hz in the axial direction. This vibration was
very likely a result of a voltage distortion in the power
line and a strong resonance condition on the motor
structure around 360 Hz in the axial direction on the
motor back.
Figure 3. This vibration spectrum recorded on the 60 HP
induction motor (drive bearing) in the axial
direction indicated a high peak at 6X line
frequency (360 Hz) due to a local structural
resonance.
Figure 4. This vibration spectrum recorded on the 60 HP
induction motor (non-drive bearing) in the axial
direction indicated a low peak at 6X line
frequency (360 Hz).
Another set of data was recorded on the 20 HP induction
motor, operating at 1790 rpm during the testing. The
vibration spectrum shows a peak at 360 Hz (6X line
frequency) with running speed sidebands (about 30 Hz)
with relatively low amplitudes (Fig. 5). The next
spectrum (Fig. 6) was recorded on the same motor
immediately after the power was turned off. All
vibration peaks of the electromagnetic origin had
disappeared immediately. The spectrum did not contain
the peak at 360 Hz and running speed sidebands. This
test confirms our presumption that the vibration peaks at
6X line frequency and running speed sidebands have an
electromagnetic nature and resulted from motor torque
and speed pulsation due to a voltage distortion.

Figure 5. This vibration spectrum recorded on the 20 HP
induction motor in the axial direction indicated a
peak at 6X line frequency (360 Hz) with running
speed sidebands (30 Hz).
Figure 7. This vibration spectrum recorded on a 150 HP
induction motor (vertical pump) in the transverse
direction indicated an extremely high peak at 2X
line frequency (7200 cpm) due to a voltage
imbalance in the power line.

Figure 6. This vibration spectrum recorded on the 20 HP

induction motor immediately after power was cut
off, indicated that all electrical peaks had
disappeared.
Case History #3
This case involved a 150 HP, 4-pole induction motor that
has driving the vertical pump. The motor rated operating
speed is 1760 rpm. Vibration data had been recorded on
this motor during a standardized monthly survey for 10
years. Data analysis showed that the vibration peak
amplitude at 2X line frequency (120 Hz or 7200 cpm)
fluctuated in a wide range during observation over that
long time period. The highest peak amplitude was
recorded at 1.0 ips (Fig. 7) and the lowest level was
recorded at 0.13 ips (Fig. 8), both in the transverse
direction. An excessive vibration of 3-phase alternate
current (AC) electric machines at 2X line frequency is
very often a result of a voltage/current imbalance.
Unstable motor vibration at 2X line frequency is very
likely a result of a voltage imbalance in the plant power
line, which also had been changed, depending on the
type of load.
Figure 8. The vibration spectrum recorded on the 150
HP induction motor (vertical pump) in the
transverse direction indicated an acceptable
vibration level at 2X line frequency (7200 cpm).
Case History #4
A vertical pump with a 100 HP, 4-pole induction motor
started to show a high vibration level at 2X line
frequency. An extremely high peak vibration amplitude
of 3.36 ips at 7200 cpm (2X line frequency) was
recorded on the top motor bearing (Fig. 9), indicating a
severe current imbalance in the stator winding. This
vibration was a result of a stator winding failure. The
motor was removed from the service, rebuilt and
reinstalled. A new set of vibration data was recorded
which showed acceptable vibration levels (Fig. 10).
 Figure 11. Vibration data recorded on the faulty pump
Figure 9. This vibration spectrum recorded on a 100 HP motor, indicating the 2X slip frequency (225 cpm)
induction motor (vertical pump) indicated an sideband peaks surrounding the running speed
extremely high peak at 2X line frequency (7200 harmonics.
cpm) due to a stator winding failure.

Figure 12. Vibration data recorded on the faulty pump

Figure 10. The vibration spectrum recorded on the 100 motor indicating a peak at 2X slip frequency.
HP induction motor (vertical pump) after motor
repair indicated an acceptable vibration level at
2X line frequency (7200 cpm).

Case History #5
This case involved a 40 HP, 2-pole induction motor that
was driving a horizontal pump. The motor was operating
at 3488 rpm during the testing. Spectra recorded on the
motor showed low frequency sidebands around running
speed harmonics, which is a sign of a low frequency
modulation in the vibration data and was a result of a
motor rotor bar problem (Fig. 11). The 2X slip frequency
(225 cpm) sideband peaks surrounding the running speed Figure 13. Vibration data recorded on the pump motor
harmonics indicated a severe rotor bar problem. Spectra after the motor replacement.
also contained a peak with an amplitude of 4.9 mils at
225 cpm (Fig. 12) as a result of a torque pulsation due to
an unsymmetrical current in the rotor cage (winding). Case History #6
The motor was finally replaced and the problem was A 60HP, 4-pole induction motor with a belt driven fan
resolved – the 1X running speed amplitude was reduced was operating on a VFD and exhibited high vibration
and the 2X slip frequency sidebands disappeared (Fig. (Fig. 14). This excessive vibration was eventually
13). determined to be the result of a faulty VFD. The highest
vibration peak of 1.98 ips at 3600 cpm (1X line
frequency) was found on the motor in the horizontal
direction (Fig. 14). This peak had completely
disappeared (Fig. 15), when the motor was operated
directly from the power line (when bypassing the VFD).
This was a sign of a severe distortion in the motor‟s
input voltage when the VFD was in operation.
Figure 14. This vibration spectrum was recorded on the
motor operating from the VFD at 60 Hz of
controller output frequency.
Figure 15. This vibration spectrum was recorded on the
motor while it operated directly from the regular
power line (while bypassing the VFD).
An excessive motor vibration at line frequency
harmonics while operating with a VFD usually results
from a voltage distortion on the motor. In this particular
case, high vibration levels were found at 1X line
frequency (3600 cpm), which is very unusual for
induction motors. It is very likely that the output
voltage/current on the faulty VFD controller contained a
direct current (DC) component during the testing. Only
the DC current component in the motor winding and the
rotating magnetic field may create a periodic torque
component at 1X line frequency (3600 cpm or 60 Hz). A
harmonic component of the full motor torque at 1X line
frequency was the source of the extremely high vibration
that was present across the whole unit.
Case History #7
DC motors have very limited applications in modern
industry. Usually, this type of an electric motor gets DC
power from rectifiers that are operating with a regular
AC power line. The major vibration problems that
appear in DC motors are generally related to improper
rectifier operation. A standard industrial rectifier
normally contains a 6X line frequency harmonic with
low amplitude in the output DC voltage. This harmonic
is a source of a DC motor torque and speed pulsation and,
consequently, an elevated vibration.
A 60 HP Extruder drive DC motor normally showed low
vibration levels (Fig. 16). A peak vibration amplitude at
21,600 cpm (360 Hz or 6X line frequency) was only 0.04
ips. Vibration data that was recorded on this motor
during a standardized monthly survey showed a
significant increase of vibration levels. The highest peak
amplitude of 0.38 ips at 21,600 cpm was found on the
motor bearings in the horizontal direction (Fig. 17). This
vibration had indicated a high level of voltage distortion
on the motor.
Figure 16. This vibration spectrum was recorded on the
60 HP DC motor during the regular operation
without any indication of problems.
Figure 17. This vibration spectrum was recorded on the
60 HP DC motor during regular operation.
Elevated vibration at 6X line frequency was
indicating an improper rectifier operation.
Case History #8
A 40 HP DC motor normally showed low vibration
levels (Fig. 18). The peak vibration amplitude at 360 Hz
(6X line frequency) was only 0.02 ips. Vibration data
that was recorded on this motor during a standardized
monthly survey suddenly started to show a significant
increase of vibration levels. The highest peak amplitude
of 1.27 ips at 120 Hz (2X line frequency) was found on
the motor bearings in the vertical direction (Fig. 19).
Spectra also contained multiples of 2x line frequency.
This vibration was indicating a high level of voltage
distortion on the motor. The vibration levels on the
motor returned to normal amplitudes after replacement
of the rectifier (Fig. 20).
Figure 18. This vibration spectrum was recorded on the
40 HP DC motor during regular operation
without any indication of problems.
Figure 19. This vibration spectrum was recorded on the
40 HP DC motor during regular operation. An
extremely high peak vibration amplitude at 2X
line frequency indicated an improper rectifier
operation.
Figure 20. This vibration spectrum was recorded on the
40 HP DC motor after rectifier replacement.
CONCLUSION
Our many years of experience demonstrates that
condition monitoring using vibration analysis provides
reliable detection of electrical problems in all types of
electric machinery and that no other technique can detect
mechanical problems in all types of rotating machines as
effectively. Vibration analysis techniques combine the
possibility for fault detection (by revealing excessive
machinery vibration), diagnosis of vibration problems in
the machinery, and faults in the machinery‟s
electromagnetic system, including internal and external
electromagnetic anomalies.
Vibration analysis has successfully identified mechanical
and electrical faults in electric machinery. Due to this,
proven precision vibration analysis should be a part of
every modern expert scheme for reliably diagnosing
electric machinery operating on ships.
REFERENCES
[1] P. Vas, Parameter Estimation, Condition
Monitoring, and Diagnosis of Electrical
Machines, Clarendon Press, Oxford, 1993.
[2] P. Tavner, L. Ran, J. Penman and H. Sedding,
Condition Monitoring of Rotating Electrical
Machines, The Institution of Engineering and
Technology, London, UK, 2008.
[3] C. W. de Silva, Vibration monitoring, testing,
and instrumentation, CRC Press, 2007.
[4] R. B. Randall, Vibration-based Condition
Monitoring, Willey, John & Sons, Inc., 2011.
[5] M. Tsypkin, “Induction Motor Condition [16] M. Tsypkin, “Vibration analysis of induction
Monitoring: Vibration Analysis Technique – a motors with pulsating electromagnetic torque”,
Practical Implementation”, International Electric Proceedings of the 20th Annual Meeting of the
Machines and Drives Conference (IEMDC), Vibration Institute, St. Louis, Missouri, pp. 169-
IEEE 2011, Niagara Falls, Canada. 178, June, 1996.
[6] S. Timoshenko, Vibration Problems in [17] M. Tsypkin, “Induction Motor Condition
Engineering, 2nd ed., Fifth Printing. Wolfenden Monitoring: Slip Frequency and Pole Pass
Press, 2008. Frequency – a Clarification of Definitions,”
[7] J. S. Mitchell, Introduction to machinery Vibration Institute Proceedings. National
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[8] D. E. Bently, C. T. Hatch, B. Grissom, 2010.
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Diagnostics, Bently Pressurized Bearing Press,
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[9] A.A. Alexandrov, A.V. Barkov, N.A. Barkova, BIOGRAPHY
V.A. Shafransky, Vibration and
Vibrodiagnostics of Electrical Equipment in Mr. Mikhail Tsypkin graduated from St. Petersburg
Ships. Sudostroenie (Shipbuilding), Leningrad, Electrical Engineering University in 1976 and St.
USSR, (In Russian), 1986. Petersburg State University in 1994, both in Russia.
[10] B. Heller, V. Hamata, Harmonic Field Effects in He is a certified member of Vibration Institute
Induction Machines, Academia, Prague, 1977. (Category III) and a member of IEEE. Mr. Tsypkin
(Elsevier Scientific Publishing Company, 1977). has been a Field Service Engineer for Vibration
[11] S. J. Yang, Low Noise Electric Motors, IEE Specialty Corporation (VSC) in Philadelphia since
Monographs in Electrical and Electronic 2001. Prior to joining VSC, he worked as a
Engineering, Oxford Science Publications, 1981.
vibration analyst for Central Ship Electrical
[12] A.A. Alexandrov, A.V. Barkov, M. Tsypkin, etc.
“The influence of asymmetrical operating Engineering & Technology Research Institute and
regimes on the alternating current electrical for VibroAcustical Systems and Technologies, Inc.
machine vibration”. Problems of Shipbuilding. (VAST), both in Saint Petersburg, Russia. He has
Section: “Ships Electro-Engineering and 36 years of the experience in machinery diagnostics
Communication”, No. 33, pp.41-50, 1981 (in and vibration analysis of electric machinery.
Russian).
[13] A.V. Barkov, M. Tsypkin, etc. “The influence of Mr. Mikhail Tsypkin can be reached at
the voltage waveform on the ship alternating mtsypkin@vib.com
current electrical machine vibration”. Problems
of Shipbuilding. Section: “Ships Electro-
Engineering and Communication”, No. 39,
pp.38-51, 1983 (in Russian).
[14] M. Tsypkin, “Vibration analysis (vibro-acoustic
behaviour) of induction motors controlled by
static-frequency converters,” in Collection Book
„VibroAcoustic of the Electrical Machines‟.
Proceedings of the Moscow Power Engineering
Institute, no. 202, pp. 57-60, 1989 (in Russian).
[15] M. Tsypkin, “The influence of the power quality
on the electrical machinery vibration”, in
Collection Book „Investigation and Calculation
of the electrical machinery VibroAcoustic
characteristics‟. Proceedings of the Moscow
Power Engineering Institute, no. 212, pp.28-33,
1989 (in Russian).