VIBRATION ANALYSIS ON

CENTRIFUGAL PUMP in B P C L
Kochi Refinery
Batch members

Athul thilak
Abdulla.H
Elisha yohannan george
Jerrin varghese


Introduction

Maintenance
Maintenance is defined as a set of activities
performed on all plants and machineries to
maintain the at the same at prime condition in
economical ways for smooth running of the
plants
Types of maintenance
Preventive maintenance
condition monitoring
breakdown maintenance
turn around maintenance
Condition Monitoring
Definition
Conditional monitoring is a method of
monitoring the condition of equipment and
machinery, which are in running condition
in respective plants.it is a type of
predictive maintenance.

Types of condition monitoring
Online
offline
Vibration monitoring can be used for
Fans
Blowers
Pumps
Compressors
Turbines
Engines

Pumps
Definision
Pump is an equipment which transfers fluids from one
point to another by pressurizing the fluid

Parts of pump
Casing
Impeller
Shaft
Bearings
Mechanical seals
Vibration analysis
Vibration
Vibration is defined as the cyclic or
Oscillating motion of a machine component
From its position of rest.
Vibration analysis helps in detercting the problem
in initial stages before they cause any damage
to machine

Vibration is caused by
Exciting force
Freedom for movement
Characteristics of vibration

Frequency
Amplitude
Displacement
Velocity
Acceleration
Phase
Acceleration Envelop

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 as the peak to peak
displacement, it is expressed in
micrometers (.001 milli meter).It is
generally at low frequencies displacement
may be the best indicator vibration
severity; typically in the frequency range
below 600 VPM.

Vibration Acceleration

Acceleration is closely related to force, and
relatively large forces can occur at high
frequencies even through the
displacement and velocity may be very
small. It is normally expressed in gsE.
Why Velocity normally used?

It gives amplitude weighing to all vibration
frequencies.
It is the only measurement parameter
where the overall vibration level can be
applied directly to a standard of vibration
severity that is when the frequencies of
vibration are unknown.

Most rotating machines produce
frequencies between 600 rpm to 12000
rpm where velocity is the most
responsive.
Vibration velocity is direct indicator
fatigue since it takes in to account both
displacement and frequency.
A measurement of overall vibration
velocity only is valid indicator of the
overall condition of a machine whether
vibration is simple (one frequency) or
more than frequency).

Vibration Velocity

It is the vibration displacement per
unit time. It is expressed in mm/s.
Vibration occurring in the 600 to 60000
CPM frequency range are generally best
measured using vibration velocity.

Vibration Frequency

The amount of time required to complete
one full cycle of vibration pattern is called
the period of vibration. Whereas vibration
frequency is the measure of the number
of complete cycles that occur in a
specified period of time. Frequency is
related to the period of vibration pattern
by the simple formula:
Frequency=1/period

The set of activities carried out
Detection
Analysis
Correction
Verification
Where to measure vibration

Usually for a pup readings are taken at
four different locations namely:
Motor Non Drive End (MNDE)
Motor Drive End (MDE)
Pump Drive End (PDE)
Pump Non Drive End (PNDE)

location readings are taken in
three directions they are


Vertical
Horizontal
Axial

IDENTIFYING THE MOST
COMMON MACHINERY
PROBLEM

Vibration due to unbalance
Vibration due to Misalignment
Vibration due to Eccentricity
Vibration due to Drive Belts
Vibration due to Electrical Faults
Vibration due to Rubbing
Vibration due to Bearings failure
SKF
It is the machine used for measuring the
vibration.
Accelerometer is connected to this
machine.
It is connected to the system using the
cable RS 232.
SKF


SKF Machine Analyst Version
2.2
The diagnosis software, saves the
condition data, presents it in
straightforward diagrams and charts, and
provides a convenient analysis of all
stored condition information.
spectrum
FFT
The transition from time domain
waveform to frequency domain spectrum
is accomplished by the Fast Fourier
Transform(FFT).A graphic depiction of the
mathematical process. The first plot
shows a normal, complex time waveform.
The complex time waveform is broken
down into a series of individual sine
waves, each one at a single frequency.
Frequency=1/period


SPECTRUM ANALYSIS
UNBALANCE CONDITION
Unbalance of rotating machine parts is perhaps the
easiest problem to pinpoint with confidence. it is due to
the non coincident of centre of mass with centre of
rotation, uncomplicated by other problems and In most
cases the data from an unbalanced condition show
CHARACTERISTICS
The vibration frequency is 1 x RPM of the
unbalanced part.
The amplitude is proportional to amount
of unbalance.
The amplitude of vibration in horizontal
and axial readings is greater than
Vertical reading(for couplings).
4. generally the ratios are,
Horizontal:axial:vertical=5:4:1

Vibration due to
Misalignment

Although machines may be well aligned
initially, several factors can affect
alignment including:
1.Operating Temperature
2.Setting of the base of foundation
3.Deterioration or shrinkage of grouting

CHARACTERISTICS
The vibration frequency is 1 x RPM; also 2
x RPM and 3 x RPM if the misalignment is
severe.
The amplitude of vibration is proportional
to misalignment.
The amplitude of vibration is high in axial
as well as the radial direction. This can be
reduced by aligning the parts at operating
temperature.
Three basic types of
misalignment

1.OFFSET MISALIGNMENT
2. ANGUALR MISALIGNMENT
3. COMBINATION ANGULAR/OFFSET
MISALIGNMENT



1. Offset misalignment causes vibration at
2*rpm
2. Angular misalignment causes vibrations at
1*rpm
3. Combinations of angular and offset
misalignments may show a combination of
1*,2*, and 3*rpm.
4. Axial reading is more than horizontal and
vertical.

Vibration due to Eccentricity

Eccentricity is happens when actual centre
of rotation differs from the geometric
centerline. It is actually a common source of
unbalance. Eccentricity can also result in
reaction forces that cannot be corrected by
simple balancing. The largest vibration occurs
at a frequency equal to 1 x RPM, similar to
unbalance but it is not. So when frequency is
1 x RPM check for unbalance and eccentricity.


Vibration due to Drive Belts
The part of machine that causing the
trouble will appear under the strobe light
of your analyzer. Thus the frequency of
vibration is key factor in determining the
nature of the trouble. Belt defects usually
show higher amplitude of vibration in the
direction that is parallel to the belt
tension.

Vibration due to Electrical
Faults
Common causes of electromagnetic
troubles are;
1.Rotor not round
2.Eccentric armature journals
3.Rotor and stator misaligned
4.Elliptical stator bore
5.Open or shorted windings
6.Shorted rotor iron


The frequency of vibration resulting
from electrical problems will be 1 x RPM.
They generally responds to the amount of
load placed on the motor as the load
changes amplitude readings also changes.




Vibration due to Rubbing


Rubbing between stationary and
rotating parts of a machine can generate
vibration at 1 x RPM, 2 x RPM and higher
frequencies. Continuous friction due to
rubbing can excite high frequency
resonance in other part of the machine
and is likely the amplitude and phase
readings will be very instable.

Vibration due to Bearings
failure
When a rolling element bearing
develops flows in the raceways and/or
rolling element, there are actually a
number of vibration frequency
characteristics that result depending up on
the extent deterioration
The primary causes of
bearing failure

1.Contamination , Including moisture
2.Overstress
3.Lack of lubrication
4.Defects created after manufacturing

ball bearing give off four distinct
frequencies


1.Fundamental train frequency(FTF)
2.Ball spin frequency(BS)
3.Outer race frequency(OR)
4.Inner race frequency(IR)

FORMULAE

FTF=rps/2[1-(Bd/pd)*cos
BS=pd/2Bd(rps)[1-(Bd/pd)*cos
OR=N(FTF)
IR=N(rps-FTF)

Where
Rps=revolutions per second of inner
race
Bd=ball diameter
Pd=pitch diameter
N=number of balls
=contact angle


FACTORS FOR MULTIPLICATION
Bearing FTF BS OR IR
FAG 6311
0.378 1.928 3.024 4.976
SKF 6311
0.382 2.003 3.057 4.943
NTN 6311
0.384 2.040 3.072 4.928
SPIKE ENERGY
A measurement design to detect low
amplitude transient impacts generated
Within ultrasonic frequency range by
microscopic surface flaws in rolling
element bearings and gears .
The acceleration signal is
processed via high pass filter and a peak
detection
The value is expressed in units of
gSE
OTHER SOURCES OF
ULTRASONIC FREQUENCIES

Cavitations
High pressure steam and air flow
Turbulence in liquids and air
Rubbing(seals,rotors,belts,guards etc)
Impact excitation(looseness or inherent in
the machines operation)
Electrical arcing

CAVITATION

As an impellers move through a fluid,low
pressure areas are formed as the fluid
accelerates around and moves past the
blades move, the lower the pressure
around it can become. As it reaches
vapour pressure ,the fliud vapourizes and
forms small bubbles of gas called
cavitation
Cavitation in pump occur in two
different forms

1. SUCTION CAVITATION
2.DISCHARGE CAVITATION

.Vibration due to Mechanical
Looseness

Mechanical looseness, and the resulting
pounding action, produces a vibration at a
frequency that is often at 2*RPM and
higher multiples of a rotating speed. This
vibration might be the result of loose
mounting bolts, excessive bearing
clearance, or a crack in the structure or
bearing pedestal.


Characteristics

harmonics indicate severe conditions of
looseness
Shows sine wave that has clipped
By changing the load and observing the
looseness can be detected

RESONANCE
Resonance is the condition whereby
the driving force applied to a structural
part is close to its natural frequency and
amplification occurs. The source of the
driving force is most likely residual
imbalance in a rotating machine attached
to the structure or broadband turbulence
due to fluid motion
charecteristics
Resonance are highly speed
sensitive,depending to some extent on
damping.damping not only decreases the
maximum amplitude of vibration but also
broadens out the response curve.rotors
also have resonances,called critical
speeds.according to the formula
F=mr
The vibratory force should increase as the
square of speed.this is true in low-speed
range.

correction
After detecting and anlysiing the
corrective action shoud be taken.
After the correction again the vibration is
measured for ensuring whether the
problem is solved.
MAINTENANCE STRATEGY
Maintenance is defined as a set of
activities performed on all plant &
machineries, to maintain the same at
prime condition for smooth running for
achievement of organizational objective.

THANKING YOU