CONDITION MONITORING OF ROTARY EQUIPMENTS

BY VIBRATION ANALYSIS

A Seminar Report

Submitted by

RENJITH M

MECHANICAL ENGINEERING DIVISION

SCHOOL OF ENGINEERING
COCHIN UNIVERSITY OF SCIENCE AND TECHNOLOGY
Cochin 682 022
SEPTEMBER 2006
 MECHANICAL ENGINEERING DIVISION
SCHOOL OF ENGINEERING
COCHIN UNIVERSITY OF SCIENCE AND TECHNOLOGY
Cochin 682 022

CERTIFICATE

This is to certify that the Seminar Report entitled “CONDITION

MONITORING OF ROTARY EQUIPMENTS BY VIBRATION ANALYSIS”
submitted by Mr. RENJITH M to the Mechanical Engineering Division towards the
partial fulfillment of the requirements for the VII Semester of the B. Tech Degree course
in Mechanical Engineering of Cochin University of Science and Technology, is a
bonafide record of the seminar talk presented by him/her on

Seminar Coordinator Seminar Supervisor

 ACKNOWLEDGEMENT

I express my deep gratitude to almighty, the supreme guide, for bestowing his blessings
up on me in my entire endeavor.

I would to like to express my sincere thanks to Dr. P.S Sreejith Head of Department of
Mechanical engineering for all his assistance

I wish to express my deep sense of gratitude to Lecturer Mr. Gireesh Kumaran

Thampi. Department of Mechanical Engineering who guided me through out the
seminar. His overall direction and guidance has been responsible for the successful
completion of the seminar.

I would also like to thank Lecturer Mr. Ajith Kumar for his valuable suggestions.

Finally, I would like to thank all the faculty members of the department of mechanical
engineering and my friends for their constant support and encouragement.
 ABSTRACT

The main function of condition monitoring is to provide the knowledge of

machine condition and of its rate of change which is essential to the operation of this
method. The knowledge may be obtained by selecting suitable parameters such as
vibration for measuring and reading its value at intervals.
Signals from vibration sensors are measured and then compared with reference
measurements in order that they may be interpreted. This involves some analysis of the
signals ranging from simple RMS amplitude measurement to vibration signature or
spectral analysis, possibly including waveform plots and extending in its most
sophisticated form to data processing and a range of physico-mathematical concepts.
Other techniques such as orbital analysis, time waveform and phase analysis have
signifance as methods for study of particular dynamic characteristics.
 CONTENTS

1. Introduction
2. Condition Monitoring
3. Classification of rotary equipments
4. Vibration
5. Transducers
6. Vibration analysis
7. Data acquisition
8. Data interpretation
9. Conclusion
10. Reference
 LIST OF TABLES

Table 1: Vibration Severity Range

Table 2: Vibration Range for Diesel Generating set for Diesel Generators
Table 3: Vibration Trouble Shooting Chart
 LIST OF FIGURES

Figure 1: Vibration Velocity

Figure 2: Vibration Acceleration
Figure 3: General Machinery Vibration Chart
Figure 4: Vibration Acceleration general severity chart
Figure 5: Moving Coil Type
Figure 6: Direct Prod Transducer
Figure 7: Accelerometer Transducer
Figure 8: Shaft Rider Accessory
Figure 9: Tri-axial Reading
Figure10: Amplitude Vs Frequency
Figure 11: Short term Amplitude Vs Time data
Figure 12: Long term Amplitude Vs Time data
Figure 13: Vibration amplitude Vs frequency data recorder identifies unbalance
Figure 14: Frequency analysis of vibration showing a bad bearing
 1
1. INTRODUCTION

Machinery distress very often manifests itself in vibration or a change in

vibration pattern. Vibration analysis is therefore, a powerful diagnosis tool, and trouble
shooting of major process machinery would be unthinkable without modern vibration
analysis.
It is natural for machines to vibrate. Even machines in the best of operation
condition will have some vibration because of minor defects as a result of
manufacturing tolerances. Therefore each machine will have a level of vibration which
may be regarded as normal or inherent.
When machinery vibration increases or becomes excessive, some mechanical
trouble is usually the reason. Machinery vibration levels just do not increases or become
excessive for no reason at all. Something causes it unbalance, looseness etc.
Each mechanical defect generates vibration in its own unique way. This makes it
possible to positively identify a mechanical problem by simply measuring and studying
its vibration characteristics.
The success of a process industry often depends on the continued, safe and
productive operation of rotating machinery. An effective maintenance programme is
vital to this kind of success. The quality of the company’s maintenance programme
determines how long the machines will run, how safe they are for the people working
around them. The benefits of a good maintenance programme are:
1. Prolonged machinery life.
2. Minimizes unscheduled down time.
3. Eliminates unnecessary overhaul.
4. Eliminates standby equipment.
5. Provides more efficient operations.
6. Increases machinery safety.
7. Improves quality performance.
8. Improves customer satisfaction.
 2
2. CONDITION MONITORING

The main function of condition monitoring is to provide the knowledge of

machine condition and of its rate of change which is essential to the operation of this
method. The knowledge may be obtained by selecting suitable parameters such as
vibration for measuring and reading its value at intervals. With condition monitoring,
repairs are carried out only when the condition of machine has deteriorated to a
predetermined level. Thus repairs or replacement of parts take place only when it has
definitely been proved that a fault exists and if it left unrepaired would result in
unsatisfactory operation or breakdown with possible damage to other machine parts and
disruption of production.

2.1 Condition Monitoring of Rotary Equipments:

1. Continuous monitoring of vibration and bearing temperature of critical
machines.
2. Vibration and noise measurement and analysis on all rotary equipments.
3. Bearing temperature monitoring by surface thermometers.
4. Condition monitoring of anti-friction bearings using shock pulse meters.
5. Measurement of RPM by stroboscope/tachometer.
6. Measurement of shaft residual magnetism.
7. Detection of cavitations in pumps by SPM.
 3
3. CLASSIFICATIONS OF ROTARY EQUIPMENTS

Rotary equipment will be classified into three categories depending upon

critically for on-stream condition monitoring as described below.
A) Category-I(Critical Machines)
These are vital machines which will be generally of high cost, high speed, too
large and complex in their design and duties and does not justify the economics of
having another spare set and breakdown of which result in immediate and serious
interruption in production.
These equipments will have continuous on-line vibration and bearing
temperature monitoring systems. These machines will be monitored for vibration on
bearing housings once a week using portable monitoring instruments.
B) Category-II (Semi-critical Machines)
These are essential machines which will be needed for normal operation of the
plant, but having stand by set, and also the running speed of which will not be very
high. Failure of such equipments will not cause immediate production loss as the stand
by set will come in line in case of failure. These machines will be monitored for
vibration on bearing housing once in two weeks. However, some of the important
machines may be monitored once in a week depending upon the requirement and
equipment behavior.
C) Category-III (Non-critical Machines)
These are desirable auxiliary and general purpose machines which, owing to its
function, can be allowed to remain temporarily out of operation without having a
serious effect on operations. These equipments will be normally having spare sets.
These machines will be monitored for vibration housings once in a month.
 4
4. VIBRATION

Vibration is simply the back and forth movement of an object from its position
of rest. It is like an oscillatory motion. Vibrations in machines above certain limits are
harmful to their functioning.
The most common causes of vibration are:
Unbalance of motor.
Looseness
Misalignment
Bend shaft
Eccentrical
Bad belt drive and drive chains
Electromagnetic forces
Hydraulic forces
4.1) Vibration Characteristics
Machines condition and mechanical problems are identified by simply noting its
vibration characteristics are:
1) Amplitude (Displacement, Velocity, Acceleration)
2) Frequency
3) Phase

4.1.1) Vibration Displacement (peak to peak)

The total distance traveled by the vibrating part from one extreme limit of travel
to the other extreme limit of travel is referred to peak to peak displacement. The
vibration displacement is usually expressed in micrometer where one micrometer equals
one thousandth of a millimeter (0.001mm).
4.1.2) Vibration Velocity
The velocity of the motion is definitely a characteristic of the vibration but since
it is constantly changing throughout the cycle, the highest peak velocity is selected for
measurement. Vibration velocity is expressed in millimeter per second peak.
 5

Fig 4.1
Vibration velocity
4.1.3) Vibration Acceleration
Vibration acceleration is another important characteristic of vibration.
Technically acceleration is the rate of change of velocity. It is normally expressed in “g”
“s” peak, where one “g” is the acceleration produced by the force of gravity at the
surface of the earth

Fig 4.2
Vibration Acceleration
4.1.4) Vibration Frequency
The amount of time required to complete one cycle of a vibration pattern is
called the period of vibration. Vibration frequency is the measure of complete cycles
that occur in a specified period of time.
Frequency = 1/period
The frequency of vibration is usually expressed as the number of cycles that
occur in each minute or CPM (cycles per minute) or number of cycles per second or
Hertz (Hz).
4.1.5) Vibration Phase
Phase is defined as the position of a vibrating part at a given instance with
reference to a fixed point or another vibrating part. Phase measurements offer a
 6
convenient way to compare one vibration motion with another or to determine how one
part is vibrating relative to another part.

Vibration Severity
There are no realistic figures for selecting a vibration limit which, if exceeded
will result in immediate machinery failure. The events surrounding the development of
a mechanical failure are too complex to set any reliable limits. On the other hand we
must have some general indications of machinery condition that can be evaluated on the
basis of vibration amplitude.

Fig. 4.3
General machinery vibration severity chart

On the fig 4.3 the horizontal axis is scaled in terms of vibration frequency and
the vertical axis in terms of displacement. The area between the diagonal lines
represents levels of vibration severity from extremely smooth to very rough.
 7
The fig 4.4 is a severity chart which works much the same way but uses velocity
and acceleration parameters and covers a higher CPM range

Fig.4.4
Vibration acceleration general severity chart
 8
5. TRANSDUCERS

Transducer is a sending device which converts one form of energy into another.
The Vibration Transducer (Pick-Up) converts mechanical vibration into an electrical
signal. There are mainly three types of Vibration Transducers.
1) Velocity Transducers.
2) Accelerometer Transducers.
3) Proximity Transducers.
Velocity Transducer and Accelerometer Transducer are called Seismic
Transducers. Proximity Transducer is called Non-contact Transducer.
5.1) Velocity Transducers
Velocity transducers respond directly to vibration velocity. Most vibration
measurement instruments have provision for processing the electrical signal from a
velocity pick up to show vibration displacement as well. In theory it is also possible to
convert signals from velocity pickups to units of acceleration, however, this is not done
in practice, because the results have been found to be unreliable.
5.1.1) Moving coil type

Fig 5.1
Moving coil type
The fig 5.1 is a simplified diagram of a seismic velocity vibration transducer.
The system consists of a coil of fine wire supported by soft spring. A permanent
magnet, firmly attached to the case of the transducer, provides a strong magnetic field
around the coil. Whenever this transducer is fixed or held tightly against a vibrating
object, this permanent magnet vibrates while the spring suspended coil of wire remains
stationary in space. When the coil of wire cuts magnet lines of force, a voltage is
 9
generated in that wire. The voltage is proportional to the velocity of motion, the strength
of the magnetic field, and number of turns of wire in the coil. The voltage generated is
transmitted by cable to a vibration meter, monitor or analyzer.
5.1.2) Direct Prod Transducer
Many times it is necessary to measure the vibration of a small light weight part
or structure. However, holding or attaching the standard velocity pickup to a small part
can actually reduce the vibration. We can solve this problem by using a direct prod
pickup such as the one shown in figure.

Fig 5.2
Direct prod transducer
The principle of operation of a direct prod pickup is identical to that of a seismic
velocity pickup. With the direct prod pickup, a thin prod extends through the end cap of
the pickup and is attached directly to the movable coil inside. To measure vibration with
a direct prod pickup, we should fasten the main body of the unit to a rigid structure to
serve as a point of reference. The tip of the prod is then attached to the vibrating part,
using a threaded tip or a special magnetic tip. We should hold the direct prod unit by
hand movements that naturally result; we should use an analyzer whose filter is tuned to
the vibration frequency of interest. The low frequency vibration dye to the hand
movements are thus eliminated from the measurements.
One of the advantages of the advantages of this type pickup is that it adds only
the weight of the weight of the prod and moving coil to the vibrating part. This makes
the pickup especially useful on small, light weight objects where the mass of a standard
seismic velocity pickup can affect the actual vibration. It is often selected for use on
balancing machines where parts may be balanced at speeds as low as 50 RPM with
excellent results.
 10
5.1.3) Piezoelectric velocity transducer
These transducers have an output that is proportional to velocity, but have no
internal moving parts. Stresses due to vibrational forces applied to the pickup cause a
crystal or special ceramic material to produce an electric charge. These are designed
specifically for low frequency applications. It can measure down to 60 CPM.
5.2) Accelerometer Transducer
An accelerometer is a self generating devise with a voltage charge output
proportional to vibration acceleration. Vibration acceleration is the measure of the rate
of change of velocity and is normally expressed in terms of “g’s”. Acceleration is a
function displacement and frequency. As a result Accelerometer is extremely sensitive
to vibration occurring at high frequencies.
5.2.1) Piezo-electric with built in amplifier

Fig 5.3
Accelerometer Transducer
The figure shows a simplified diagram of piezo-electric with built in amplifier.
When this pickup is fixed or held against a piece of vibrating machinery, the mechanical
vibrations are passed through the frame to a piezo-electric material. This material has
the ability to generate an electrical charge in response to a mechanical force applied to
it. In this instance mechanical vibration producers the force and the piezo-electric
material responds by generating an electrical charge that is proportional to the amount
of vibration acceleration.
5.3) Non-contact (Proximity) Transducers
Many high speed machines consist of relatively light weight motors mounted in
massive cases and rigid bearings. Because of weight and stiffness of the massive
machine case and bearings, externally mounted vibration and acceleration pickups often
 11
show little outward evidence of motor or shaft vibration. It is necessary to measure the
actual shaft vibration in order to know when bearing clearances are in danger. It is
displacement transducer measuring the shaft displacement relative to it fixing object.
5.4) Shaft Rider Accessory
A shaft stick is usable for periodic vibration checks and some analysis and in-
place balancing operations. When it is necessary to monitor shaft vibration for extended
periods of time, it is recommended that we use a shaft rider.
The figure shows that a shaft rider is permanently installed in the bearing
housing. It consists of a spring loaded probe that is held firmly against the rotating shaft
so that is held firmly against the rotating shaft so that it accurately follows shaft motion.

Fig 5.4
Shaft rider accessory
 12
6. VIBRATION ANALYSIS

Vibration Analysis is a two step process involving the ACQUISITION and

INTERPRETATION of machinery vibration data. Its purpose is to determine the
mechanical condition of a machine and specific mechanical or operational defects.
The Data Acquisition procedure is a means of systematic measuring and
recording of the vibration characteristics needed to analyze a problem.
The Data Interpretation involves comparing the recorded data with the details of
the machine, like its speed or speeds, its foundations, the construction details etc. then
the characteristic of vibration typical of various defects are compared with the
characteristics that have been measured. By this, one can pinpoint the trouble and take
corrective measures.
 13
7. DATA ACQUISITION

Data acquisition is the essential first step in vibration analysis, since the right
data must be acquired under the right conditions to completely interpret a machine’s
condition.
Data acquisition can be done in several ways depending on the available
instruments. Apart from data acquisition, additional data acquisition procedure such as
semi-automatic, automatic and real time analysis are employed where the job can be
quicker and more accurate.
In the semi-automatic method, the operator manually adjusts the filter through
the frequency ranges, while the data is automatically recorded in a recorder. These types
of plots are records of vibration amplitudes in the ‘Y’ axis and the frequencies in the
‘X’ axis. Such a plot is called Machinery Vibration Profile (Signature) and the analysis
of the same is called as Signature Analysis.
Automatic data acquisition is the term used to describe the procedure of
obtaining the data, where the instrument automatically plots the vibration profiles. This
type of instrument incorporates and electronically swept filter as well as provisions for
simultaneous plotting of data with the recorders.
7.1) Selection of Measurement Parameters
The various measurement parameters are displacement, velocity, acceleration:-
7.1.1) Displacement
Displacement can be measured with both velocity and acceleration pickups. This
is accomplished by means of integrator circuits that are normally included in the circuit
of vibration meters and analyzers. Pickups that respond directly to vibration
displacement are readily available, but are usually used in the non-contact pickups.
7.1.2) Velocity
Velocity can also be measured with both velocity and acceleration pickups.
Seismic and piezoelectric velocity pickups obtain vibration directly. The output from an
accelerometer can be integrated to produce the equivalent of a velocity measurement,
down to about 3Hz, or 180 CPM.
 14
7.1.3) Acceleration
Acceleration should be measured only with an accelerometer. It is theoretically
possible to differentiate signals from a velocity transducer to produce acceleration
readings, but this would be needlessly complicated and expensive.
7.2) Common Types of Measurements
The common types of measurements are:-
1) Overall vibration amplitude measurements.
2) Amplitude Vs Frequency measurements.
3) Amplitude Vs Time measurements.
4) Phase measurements.
They are described below:-
7.2.1) Overall vibration amplitude measurements.
Overall vibration amplitude measurements provide a quick check of general
machinery condition. A vibration meter or analyzer can be used for these
measurements. This measurement is generally manually recorded in tabular form, or the
data automatically stored in memory for computer based automated instruments.
7.2.2) Amplitude Vs Frequency measurements.
Amplitude Vs Frequency measurements provide frequency spectrum which is
used to pinpoint the problem to a specific frequency or range of frequencies. Full
capacity or advanced check analyzers are required to take these measurements. Data can
be recorded manually in tabular form, or by semi automatic or automatic swept filter
analysis with tabular or graphic hard copy recording of the data. FFT type analyzer can
also provide tabular/graphic hard copy of visual display of the data.
It is estimated that over 85% of the mechanical problems occurring on rotating
machinery can be identified by displaying the vibration Amplitude Vs Frequency data.
Importance of tri-axial readings
It is common practice to record the Amplitude Vs Frequency data measured in
the horizontal, vertical and axial pickup directions at each bearing of the machines
being analyzed. Obtaining measurements in all the three directions is extremely
important for distinguishing between various mechanical problems. eg. Unbalance,
Misalignment, bend shaft structural weakness (loose parts) will generally cause
vibration at a frequency 1X RPM. Unbalance will almost always produce high
amplitudes in the horizontal direction while lower amplitudes in the axial direction.
Misalignment of couplings and bearings or a bend shaft will generally show relatively
 15
high amplitude of vibration in the axial direction. Amplitudes due to structural
weakness, loose parts are shown in Vertical direction.

Fig 7.1
Vibration are normally taken in horizontal, vertical and axial directions on a machine bearing
 16

Fig 7.2
Amplitude Vs Frequency
7.2.3) Amplitude Vs Time measurements.
Time measurements can be made during machine operation to detect vibrations
that would not be apparent from Amplitude Vs Frequency analysis. Amplitude Vs Time
measurements can be made for very fast transient vibrations or for slowly occurring
vibrations. For fast transient vibrations use an oscilloscope with the horizontal axis
scaled in milliseconds. For slowly varying vibrations use a recorder with the horizontal
axis scaled in seconds. It can be taken with a DC recorder connected to an analyzer with
that built-in-capability.
 17

Fig 7.3
Short term Amplitude Vs Time data.

Fig 7.4
Long term Amplitude Vs Time data

7.2.4) Phase measurement

Phase measurements are important when analyzing mechanical problems in
machinery. Phase is defined as the position of a vibrating part at a given instance with
reference to a fixed point or another vibrating part. Phase measurements offer a
convenient way to determine how one part is vibrating relative to another part.
To obtain phase measurements, an analyzer with a strobe light or remote
reference pickup is required. The use of strobe light necessities visual observation of the
rotating shaft and the capability to fire the strobe light with vibration signal in order to
 18
obtain phase. The remote phase pickup, which is usually an electromagnetic pickup,
non-contact transducer or photocell must be installed so that to observe mechanical
protrusion (depression) or a reflective mark on the shaft.
The strobe light measurement involves observing the angular position of the
reference mark that appears under the strobe light, while the remote reference pickup
provides phase readout (digital or analog) using a meter on the analyzer.

9. DATA INTERPRETATION

Once the necessary information have been collected by manual, or semi-

automatic or automatic, the next step is to review and compare the reading with the
characteristics of vibration typical of various types of troubles. A key to this comparison
is the frequency. If a machine part has some defect, the frequency of vibration resulting
from this defect will some multiple of the RPM. The multiple is different for different
 19
defects. Also there are some defects which will produce vibration frequencies that are
not related with the RPM.
7.1) Causes Of Vibration
The major causes of vibration on Rotary machines are:-
1) Unbalance
The horizontal, vertical and axial vibration signatures presented in the figure
given below illustrate typical Amplitude Vs Frequency analysis data resulting from an
unbalance condition. It can be noted that, the predominant vibration occurs at 2200
CPM corresponding to the 2200 RPM fan speed. Since the amplitude of vibration in the
axial direction is relatively low compared to the radial amplitudes, a bent shaft or
misalignment is not indicated. The appearance of small amplitudes at the harmonic
frequencies is common and does not necessarily indicate any unusual problems such as
mechanical looseness.

Fig 7.1
Vibration amplitude Vs frequency data recorder identifies unbalance
2) Mechanical looseness
The vibration may be the result of loose mounting bolts, excessive bearing
clearance, a crack or break in the structure or bearing pedestal, a rotor which is loose on
the shaft, or some other loose machine component. The vibration characteristic of
mechanical looseness will not occur unless there is some other exciting force such as
unbalance or misalignment can result in large amplitudes of looseness vibration. The
 20
vibration due to looseness can be detected from Amplitude Vs Frequency when taking
the reading in vertical direction.
3) Misalignment
Misalignment is an extremely common problem. Misalignment, even with
flexible couplings, results in two forces, axial and radial vibration. The significant
characteristic of misalignment and bent shafts is that vibration will be noted in both the
radial and axial directions. As a result, a comparative axial vibration is the best
indication of misalignment or a bent shaft.
4) Defective antifriction bearing
Flaws on the raceways, balls or rollers of rolling element bearings cause high-
frequency vibrations and the frequency is not the multiple of the shaft RPM. The
amplitude of vibration depends on the extent of the bearing fault. The natural frequency
vibrations typically occur as vibration peaks in the 10,000 to 100,000CPM. Defects in
the bearing components can generate vibration peaks at frequencies related to the
bearing geometry. The vibration generated by the bearing is not normally transmitted to
other points of the machine.

Fig 7.2
Frequency analysis of vibration showing a bad bearing
The other reasons for the vibration are:-
1) Defective sleeve bearing.
2) Defective gears.
3) Eccentricity.
4) Oil whirl.
5) Bad drive belts or chain.
 21
6) Electrical defects.
7) Rubbing.
8) Bend shaft.
9) Cavitation.
10) Flow turbulence.

7.2) Recommended Method of Vibration Classification (As Per ISO 2372)

The machines are classified into five groups as per ISO 2372.
They are:
Class I
Individual parts of engines and machines integrally connected with the complete
machine in its normal operating condition (Production electrical motors of up to 15KW
are typical examples of machines in this category).
Class II
Medium sized machines (typically electrical motors of 15-75KW output)
without special foundations rigidly mounted engines or machines (up to 300KW) on
special foundations.
Class III
Large prime movers and other large machines with rotating mass mounted on
rigid and heavy foundations which are relatively stiff in the direction of vibration
measurement.
Class IV
Large prime movers and other large machines with rotating masses mounted on
foundations which are relatively soft in the direction of vibration measurement
(eg.Diesel-generator sets, especially those with light weight substructures).

Class V
Machines and mechanical drive systems with unbalancable inertia effects (due
to reciprocating parts) mounted on foundations which are relatively stiff in the direction
of vibration measurement.
Class VI
 22
Machines and mechanical drive systems with unbalanceable inertia effects (due
to reciprocating parts) mounted on foundations which are relatively stiff in the direction
of vibration measurement. Machines with rotating slack-coupled masses such as beater
shafts in grinding mills, machines like centrifugal machines with varying unbalances
capable of operating as self contained units without connecting components, vibrating
screens, dynamic fatigue-testing machines and vibration exciters used in process plants.

In practice, instead of good/Allowable/Just permissible, the following colloquial

is used to stipulate the health condition of machines.
Good
Satisfactory
Just satisfactory
Unsatisfactory
Dangerous

VIBRATION SEVERITY RANGE

(In accordance with ISO 2372)
Velocity –mm/sec
Class A-Good B-Usable C-Still acceptable D-Un acceptable
 23

0-15KW Class I 0.71 1.8 4.5 45

15-75KW Class II 1.12 2.8 7.1 45

>75KW Class III 1.8 4.5 11.2 45
Turbocharge
Class IV 2.8 7.1 18 45
r

Table 7.1
Vibration Severity Range

DIESEL GENERATING SET FOR DIESEL GENERATORS

(WARTSILA,ANMAR,FUJI,DAIHATSHU,MERLESS,BLACKSTONE,SKL,SK
ODA,CATTERPILLER ETC)
Limit parameter is peak-velocity in mm/sec.
Sl. No LOCATION S.LIMIT J.S.LIMIT
MACHINE BASE FIXING
1. 10 20
LOCATION
CRANK CASE CENTRE
2. 10 20
LINE
CRANK CENTRE LINE
3. 10 20
CYLINDER HEADS
4. 10 20
TURBOCHARGER
5. 15 30
PILLOW BLOCK BEARING
6. 15 25
ALTERNATOR BEARING
7. 05 15
GENERATOR BEARING
8. 05 15

Table 7.2
Vibration Range for Diesel Generating Set For Diesel Generators

VIBRATION TROUBLE SHOOTING CHART

Frequency of
Nature of fault domain vibration Direction Remarks
(RPM)
 24
Rotating members A common cause of excess
1X RPM Radial
out of balance vibration in machinery
Misalignment & Usually 1X RPM. Radial &
A common fault
Bent shaft Often 2X RPM. Axial
Damaged Rolling Impact rates for the
Radial & Uneven vibration level, often
Element Bearings individual bearing
Axial with shocks, impact rates
(Ball, Roller etc) components.
Sub harmonics of Looseness may only develop at
Journal bearing
shaft rpm,exactly ½ Radial operating speed and high
loose in housing
or 1/3 rpm temperature(eg.turbomachines)
Oil film whirl or
Slightly less than Applicable to high speed
whip in journal Radial
half speed machines.
bearing
Vibrations exited when passing
through critical speed are
Hysteresis whirl Shaft critical speed Radial
maintained at higher shaft
speeds.
Tooth meshing
Side bands around tooth
frequency (shaft
Damaged or worn Radial & meshing frequencies detectable
rpm X number of
gear Harmonics with very narrow band analysis
teeth) and
and spectrum
harmonics
Mechanical Radial & Also sub harmonics for loose
2X RPM
looseness Axial journal bearings.
The precise problem can
Faulty belt drive 1,2,3,4 X RPM Radial usually be identified with the
help of a strobe light.
Unbalanced Radial &
1X RPM Easily felt by hand touch
reciprocating Axial
Increased Blade passing
Radial & Increased level indicate
turbulence or frequencies and
Axial increasing turbulences
recirculation harmonics
No phase difference with
Cavitations 1X RPM Radial
strobe light
Electrical induced 1X RPM or 1 or 2 Radial & Disappear immediately when
vibrations times synchronous Axial turn-off the power
 25

frequency

Table 7.2
Vibration Trouble Shooting Chart

8 CONCLUSION

Condition monitoring by vibration analysis gives information about the

changing condition of the equipment thus enabling the avoidance of total breakdown
and can have reduced time. Prediction of residual life enables the equipment to be
stopped before they reach critical condition and thus safe operation is ensured.
Improved production quality is achieved through condition monitoring. By condition
 26
monitoring, detection of incipient faults and determination of plant condition enable
forecasting of maintenance demands.

9 REFERENCE

1. S.S.Rattan, Theory of Machines, Tata McGraw-Hill, New Delhi, 2004.

2. Vibrotech, Training Manual, Chennai.

 27
3. IRD Mechanalysis, Instruction Manual.