Condition Monitoring Division

Basic Vibration Course

PT. Andritz Hydro
6-8 May 2024
Condition Monitoring Division

Basic Vibration Course

Introduction
Condition Monitoring Division
Introduction
Evolution of Machinery Maintenance
MACHINERY AVAILABILITY,
RELIABILITY & PERFORMANCE HIGH AVAILABILITY
HIGH RELIABILITY
HIGH PERFORMANCE
LESS MAINTENANCE COST

PREDICTIVE
MAINTENANCE

PREVENTIVE
MAINTENANCE
CORRECTIVE
MAINTENANCE

INDUSTRIAL
TECHNOLOGY PROGRESSION PRESENT
REVOLUSION

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Introduction
Evolution of Machinery Maintenance

• Operate till breakdown

No action if not fatal failure, actually is not maintenance but repair only, so
called corrective maintenance
• Time-based maintenance
Periodical preventive action (i.e. parts replacement) to prevent failure, so
called Preventive Maintenance (PM)
• Condition-based maintenance
Periodical condition monitoring to predict failure by evaluating the trend of
some parameters from time to time, so called Predictive Maintenance
(PdM) or Condition Monitoring (CM)

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Introduction
Evolution of Machinery Maintenance – Corrective Maintenance
“Fix it only if it is broken”
• A passive/reactive philosophy
No measures are taken to anticipate and prevent failure
• Very expensive in case of:
 Fatal damage – failed component could harmfully affect other
components
 Safety risk – related to human, environment or the whole plant
 Unplanned downtime – inconvenient production stoppage, loss revenue
 Unplanned repair work – labor, tools & equipment, spare parts
 Product waste – coagulation, freezing, spoiling, …
 Uncertain spares inventory – aging spare or no spare

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Introduction
Evolution of Machinery Maintenance – Preventive Maintenance
“Fix it before it is broken”
• A proactive philosophy
Maintenance on regular time basis to prevent failure regardless the condition
• Also costly in case of:
 Regular extra downtime – frequent production stoppage for maintenance
 Regular extra work – labor, tools & equipment
 Longer duration of maintenance – more tasks to do
 Unnecessary parts replacement – parts that reached ‘lifetime’ in many
cases still good for longer period usage
 Risk of premature failure – sometime parts don’t reach its “lifetime”
 Risk of reassembly errors – more disassembly, more error probability

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Introduction
Evolution of Machinery Maintenance – Predictive Maintenance
“Fix it only if it will be broken”
• An advanced proactive philosophy
Determines the condition of machinery as it operates, to schedule the most
effective and efficient repair of problem component prior to failure
 Higher machine availability, reliability and performance
 Greater safety & environment
 Better product quality
 Longer machinery life
 The most cost effective
 Mandatory for critical machinery

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Introduction
Predictive Maintenance – the Concept

• Detection of a developing fault

• Trending of the fault
• Operate the machine up to but before failure
• Plan maintenance ahead of time and save money
• Focus on problem component and solve the root cause Failure

Machine condition
Danger Level

Alert Level
Fault detection

Lead time
before failure
Running Time

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Introduction
Predictive Maintenance – the Tools

• Vibration monitoring and analysis

• Thermography
• Lube/oil analysis
• Current analysis
• Ultrasound/acoustic analysis
• Thickness/corrosion check
• Process parameter monitoring (temperature,
pressure, flow, …)

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Introduction
Predictive Maintenance – some Pictures

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Introduction
Predictive Maintenance – some Pictures

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Introduction
Predictive Maintenance – some Pictures

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Introduction
Predictive Maintenance – some Pictures

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Introduction
Vibration Monitoring and Analysis – Outline

• Vibration Basics
• Vibration Data Acquisition
• Vibration Condition Evaluation
• Vibration Fault Analysis

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Condition Monitoring Division

Basic Vibration Course

Vibration Basics
Condition Monitoring Division
Vibration Basics
Fact about Rotating Machinery

• All rotating parts generate vibration

• The vibration indicates the healthy condition of the
machine
• In general, worst the machine condition, higher the
vibration
• Individual components on a machine train generate
vibration signals unique to each component

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Vibration Basics
What is Vibration? – Sine Wave Model

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Vibration Basics
What is Vibration? – Displacement, Velocity, Acceleration

• Displacement is the change in distance or position of

an object relative to a reference
• Velocity is the first derivative of displacement as a
function of time, it is the rate of change of
displacement
• Acceleration is the second derivative of displacement,
it is the rate of change of velocity

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Vibration Basics
What is Vibration? – Displacement, Velocity, Acceleration

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Vibration Basics
What is Vibration? – the Unit and Conversion

•Displacement (D)
mils or micron (μm)
•Velocity (V) V = D.ω
inch/sec (ips) or mm/sec A = V.ω = D.ω2
ω = 2πf
•Acceleration (A)
g or inch/sec2 (ipss) or m/sec2 Beware of the unit consistency
when do conversion!

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Vibration Basics
What is Vibration? – Exercise
Exercise 1
An electric motor runs at speed 1500 rpm. The
vibration measured in unit of velocity is 4.5 mm/sec.
How much is the vibration in unit of displacement?

f  25 Hz
π  3.14
4.5 mm/sec
D  28.66x10 3 mm  28.66 μm
2x3.14x25/sec

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Vibration Basics
What is Vibration? – Exercise
Exercise 2
A pump runs at speed 3000 rpm. The vibration
measured in unit of displacement is 1 mils. How much
is the vibration in unit of acceleration?

f  50 Hz
π  3.14
A  1 mils x (2x3.14x50/sec) 2  98.596x103 mils/sec2  98.596 ipss

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Vibration Basics
What is Vibration? – Exercise
Exercise 3
A fan runs at speed 1200 rpm. The vibration measured
in unit of acceleration is 0.1 g. How much is the
vibration in unit of velocity?

f  20 Hz
π  3.14
g  9.8 m/sec 2
0.1x9.8 m/sec 2
V  7.8x10-3 m/sec  7.8 mm/sec
2x3.14x20/sec

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Vibration Basics
What is Vibration? – Peak, Peak to Peak, RMS

Peak is distance from neutral to upper position or from neutral to lower

position
Peak to Peak is distance from upper position to lower position
RMS is effective value, by mathematic the formula is Root-Mean-Square

Peak to Peak = 2x Peak

RMS = ½ √2 x Peak = 0.7x Peak
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Vibration Basics
What is Vibration? – Amplitude, Frequency, Phase

Amplitude A
1
a (t) = A sin(θ0+ωt)
Frequency f 
T A
Phase θ 0

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Vibration Basics
What is Vibration? – Amplitude, Frequency, Phase

• Vibration Amplitude indicates the severity of problem

How much is it vibrating?
• Vibration Frequency indicates the source of problem
What is vibrating?
• Vibration Phase indicates the behavior of problem
How is it vibrating?

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Vibration Basics
Vibration Frequency – What is vibrating?

• Individual components on a machine train generate

vibration at each respective frequency

Vibration
amplitude

Frequency

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Vibration Basics
Vibration Frequency – What is vibrating?
Example
• Motor speed 1500 rpm (25 Hz)
• Gear ratio 1:2 (speed reducer)
• Fan speed 750 rpm (12.5 Hz)

Vibration from component

related to motor speed 0s 0.08 s

Vibration from component

related to fan speed 0s 0.08 s

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Vibration Basics
Vibration Frequency – the Unit

• RPM (Revolutions Per Minute) – Speed

• CPM (Cycles Per Minute) – Frequency
• CPS (Cycles Per Second) or Hz (Hertz)
• Orders of Running Speed – how many times event
occurs per shaft revolution (1x rpm, 2x rpm, …)

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Vibration Basics
Sum of Vibration in Time Domain

f1

+
f2

=
f1 + f2

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Vibration Basics
Sum of Vibration in Time Domain

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Vibration Basics
Sum of Vibration in Frequency Domain

f1
f
+ f1

f2

= 2f1 f

f1 + f2

f1 2f1 f

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Vibration Basics
Vibration Amplitude and Frequency

Questions?

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Vibration Basics
Vibration Phase – How is it vibrating?
Example
180 deg different between two vibration sources

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Vibration Basics
Vibration Phase – Relative to a Reference

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Vibration Basics
Vibration as Result of Force x Mobility

Vibration
Internal
Forces

Structural
Vibration = Forces x Mobility Mobility

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Vibration Basics
Vibration as Result of Force x Mobility

Forces x Mobility = Vibration

DD

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Vibration Basics
Vibration as Result of Force x Mobility

h(t)
Force Input Impulse
response
function t
Output Point 1
Point 2

H(f)
Mobility
Point 1
t f
H(f)
Mobility
Point 2
f

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Vibration Basics
Vibration as Result of Force x Mobility
Measured vibration from the same source may be different from point to point

Point 1

Forces x Mobility = Vibration

Point 2

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Vibration Basics
Vibration Basics

Questions?

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Vibration Basic Course

Vibration Data Acquisition
Condition Monitoring Division
Vibration Data Acquisition
In the past

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Vibration Data Acquisition
In the past

• The first portable vibration measuring instrument

manufactured by Schenck, introduced at an exhibition
in Leipzig in 1925

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Vibration Data Acquisition
Types of Machine’s Vibration Measurement

Absolute
Bearing Vibration

Relative Absolute
Shaft Vibration Shaft Vibration

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Vibration Data Acquisition
Types of Machine’s Vibration Measurement
– Bearing Vibration or Shaft Vibration?

• Rule 1: The vibration measurement that delivers the

highest information content should be chosen
• Rule 2: If no experience is available, the maximum
information will be obtained by measuring
Relative shaft vibrations on machines with sleeve
bearings
Absolute bearing vibrations on machines with
rolling-element bearings

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Vibration Data Acquisition
Measuring Bearing Vibration

• Horizontal direction
• Vertical direction
• Axial direction

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Vibration Data Acquisition
Measuring Shaft Vibration

• Using two sensors, perpendicular to the shaft with

distance 90o each other
A B

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Vibration Data Acquisition
Vibration Sensors

• Displacement sensor
• Velocity sensor Acceleration
• Acceleration sensor
• Phase sensor (tacho)

Velocity

Displacement

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Vibration Data Acquisition
Displacement Sensor

• With external oscillator

• With integrated oscillator

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Vibration Data Acquisition
Displacement Sensor

• Is a non contacting sensor

• Electromagnetic field from a coil at the sensor tip
induces eddy-currents in conducting material through
air gap, which is proportional to the gap
• So called eddy-current probe or sometime also called
proximity probe
• The probe, oscillator and cable are a set of measuring
chain that cannot freely substituted

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Vibration Data Acquisition
Displacement Sensor

• Measure relative distance between two surfaces

• Monitor shaft vibration
• Used on machine with fluid film bearing (journal)
• Accurate low frequency response
• Limited high frequency sensitivity
• Require external power source
• Influenced by material density variations and
mechanical run-out

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Vibration Data Acquisition
Displacement Sensor

• More difficult to install compared to other sensor type

• Easier to damage especially at sensor tip

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Vibration Data Acquisition
Displacement Sensor – Properties

• Frequency range 0 ... 1 kHz

• Linear measuring range 1.5 / 2 / 4 / 8 mm and larger
• Transmission factor 8 / 4 / 2 mV/µm

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Vibration Data Acquisition
Displacement Sensor – Typical Transmission Curve
0

GAP voltage [V] -5

-10

-15

-20
0 0,5 1,0 1,5 2,0 2,5 3,0
s [mm]

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Vibration Data Acquisition
Displacement Sensor – Determining the Sensitivity
0

GAP voltage [V]

-5

ΔU -10
DU
Sensitivity 
Δs
-15 Ds

-20
0 0,5 1,0 1,5 2,0 2,5 3,0
s [mm]

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Vibration Data Acquisition
Displacement Sensor – Other Application

• Thrust
• Shaft expansion

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Vibration Data Acquisition
Velocity Sensor

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Vibration Data Acquisition
Velocity Sensor

• Consists of a magnetic core suspended on springs and

surrounded by a coil of wire. Relative motion between
the coil and core produces an output voltage
proportional to velocity

1 Helical spring
2 Spool

3 Spool carrier

4 Permanent magnet

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Vibration Data Acquisition
Velocity Sensor

• Attached to bearing housing to monitor absolute

bearing vibration
• Used on machine with rolling element bearing
• Effective in low to mid frequency range (10 Hz to
around 1.5 kHz)
• Active sensor, requires no power
• Influenced by strong magnetic field
• Mechanical moving inside can stick or fail

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Vibration Data Acquisition
Acceleration Sensor

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Vibration Data Acquisition
Acceleration Sensor

• Consists of piezoelectric crystal elements and a mass.

When the piezoelectric crystal is stressed by the mass
due to vibration from machine, it produces an
electrical output proportional to acceleration.

1 2
3
4
5
7
5 1 Housing
2 Charge amplifier
3 Pre-tensioning element
6 4 Seismic mass
5 Piezo-electric element
6 Base
7 Cable connection

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Vibration Data Acquisition
Acceleration Sensor

• Wide frequency range (near 0 to above 40 kHz)

• Good for high frequency response but low sensitive at
low frequency
• Rugged construction and not Influenced by magnetic
field
• Some models available for high temperature
• Small size and light weight, suitable for portable survey
• Requires power

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Vibration Data Acquisition
Photo-electric Phase/Reference/Trigger/Speed Sensor

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Vibration Data Acquisition
Sensor Attachment

• Using extension probe

• Using magnet mounting
• Using threaded stud

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Vibration Data Acquisition
Sensor Attachment – Extension Probe

Sensor

Probe

Center-punch Dimpled plate

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Vibration Data Acquisition
Sensor Attachment – Extension Probe

• Usable frequency range of accelerometer using

extension probe:
 Aluminum 1 to 700 Hz
 Steel 1 Hz to 1 kHz
• Easy to attach
• Care required when holding the probe
• Offline measurement, suitable for measurement point
that is not possible to attach magnet

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Vibration Data Acquisition
Sensor Attachment – Magnet Mounting

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Vibration Data Acquisition
Sensor Attachment – Magnet Mounting

• Usable frequency range of accelerometer using

magnet mounting: 1 Hz to 2,2 kHz
• Easy to attach, operator hands-free
• Magnet should sit flat and surface should clean
• Ferrous material required
• Offline measurement

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Vibration Data Acquisition
Sensor Attachment – Threaded Stud

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Vibration Data Acquisition
Sensor Attachment – Threaded Stud

• Usable frequency range of accelerometer using

threaded stud: 1 Hz to 20 kHz
• Best possible measurement reproducibility
• Requires more preparation work to install the sensor
• Online measurement, permanent installation

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Vibration Data Acquisition
Measurement Parameter Setup

• Measurement unit and signal detection (e.g. mm/sec rms)

• Frequency Setting (e.g. 10 Hz to 1 kHz)
• Line resolution (e.g. 1600 lines)
• Average (e.g. frequency domain, 16x)

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Vibration Data Acquisition
Measurement Parameter Setup – Frequency Setting

• Lower and upper frequency limit are set according

what frequency range we are interested
• Frequency setting will affect the resolution

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Vibration Data Acquisition
Measurement Parameter Setup – Frequency Setting

Component Upper Frequency Limit (Fmax)

Shaft vibration 10x rpm
Gearbox 3x Gear Mesh Frequency
Rolling element bearing 10x Ball Pass Frequency
Pump 3x Vane Pass Frequency
Motor/generator 6x Line Frequency
Fan 3x Blade Pass Frequency
Sleeve bearing 10x rpm
Engine 12x rpm

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Vibration Data Acquisition
Measurement Parameter Setup – Frequency Setting

Application Lower Frequency Limit (Fmin)

Machinery monitoring 1% Fmax

General measurement 3 to 10 Hz

Gear Box 0.25x GMF (or 20x rpm)

Special application 10 to 20x rpm

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Vibration Data Acquisition
Measurement Parameter Setup – Frequency Setting
Example
Driving gear 52T, driven gear 17T, 600 rpm driving shaft
How do we set the frequency setting?

GMF = T1 x rpm1 = T2 x rpm2 = 52 x 10 Hz = 520 Hz

Fmax > 3x GMF = 1560 Hz  1600 Hz
Fmin < 0.25x GMF = 130 Hz  100 Hz

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Vibration Data Acquisition
Measurement Parameter Setup – Line Resolution

• Line resolution is frequency range divided by number

of line on the frequency axis
• Higher the resolution, more accurate the spectrum for
analysis
• But consequently, higher the resolution, longer time
required for data acquisition

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Vibration Data Acquisition
Measurement Parameter Setup – Average

• Average is statistical average to smooth out varying

amplitude in order to improve measurement accuracy
• Average can be done in time domain (original signal)
or in frequency domain (FFT spectrum)
• Higher the number of average, more accurate the
data, but consequently takes longer time

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Condition Monitoring Division

Vibration Basic Course

Vibration Condition Evaluation
Condition Monitoring Division
Vibration Condition Evaluation
Evaluation Method

• Comparison of measurements with limits from

standards and guidelines
• Comparison of measurements with limits from the
machine manufacturer
• Evaluation on the basis of experience and data from
measurements by the operator at identical or similar
machines
• Evaluation of the measurements over time (Trend)

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Vibration Condition Evaluation
Measurement over Time

• To do trending, the measurement condition should be

the same:
Same measurement point
Same attachment method
Same parameter setup
Same speed
Same load
• Trend is the best way to evaluate machine condition
and perform Predictive Maintenance

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Vibration Condition Evaluation
Evaluation According to ISO 10816

• Mechanical vibrations – Evaluation of vibrations from

machines by measurement on non rotating parts
Part 1 General instructions
Part 2 Large, stationary steam turbine/generator sets with power above 50
MW
Part 3 Industrial machines with nominal power above 15 kW and nominal
speeds between 120 rpm and 15000 rpm; measured on-site
Part 4 Machine sets with gas turbine drive, excluding aircraft jet engines
Part 5 Machine sets in hydro-electric power and pumping plants
Part 6 Reciprocating machines with power above 100 kW

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Vibration Condition Evaluation
Evaluation According to ISO 10816

• Application
Operational monitoring and acceptance tests of
machines
No torsional vibrations
No enviromental vibrations

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Vibration Condition Evaluation
Evaluation According to ISO 10816

• Evaluation zones
Zone A
Vibrations in newly installed machines
Zone B
Machines may be operated continuously without restriction
Zone C
Machines may be operated only for a limited time
Zone D
Vibrations are excessive and may cause permanent damage to the
machines

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Vibration Condition Evaluation
Evaluation According to ISO 10816

• Guideline for measurement and evaluation

Criterion I
The maximum measured radial vibration value* may
not exceed a specific maximum value
*effective value RMS in the frequency range 10 Hz to 1 kHz vibration
velocity resp. vibration displacement
at speeds < 600 rpm, frequency range 2 Hz to 1 kHz

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Vibration Condition Evaluation
Evaluation According to ISO 10816

• Limit values for vibration monitoring

When measuring at a number of points, the maximum measured vibration
value is the vibration severity of the machine

PRE-ALARM limit = Ref. value + 25% x (upper limit of zone B)

MAIN ALARM limit = Ref. value + 25% x (upper limit of zone C)

When no baseline value is available:

PRE-ALARM limit < 1.25 x (upper limit of zone B)
MAIN ALARM limit < 1.25 x (upper limit of zone C)

or other values when machines are well known

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Vibration Condition Evaluation
Evaluation According to ISO 10816

• Criterion II
The maximum measured radial vibration value*
should not exhibit an appreciable increase or decrease
relative to a reference value
*effective value RMS in the frequency range 10 Hz to 1 kHz vibration
velocity resp. vibration displacement
at speeds < 600 rpm, frequency range 2 Hz to 1 kHz

Appreciable deviations from reference value typically > 25% x (upper limit of
zone B). Diagnostic investigation is appropriate, even though the limit value
may not have been reached

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Vibration Condition Evaluation
Evaluation According to ISO 10816 – Part 3

• Steam turbines with power up to and including 50 MW

• Steam turbines with power above 50 MW when service speed is lower than
1500 rpm or higher than 3600 rpm
• Gas turbines with power up to and including 3 MW
• Turbo-compressors
• Pumps
• Generators
• Electric motors
• Blowers
• Fans with power up to and including 300 kW

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Vibration Condition Evaluation
Evaluation According to ISO 10816 – Part 3 Group 1

• Large machines with nominal power above 300 kW; electrical machines with
shaft height H ≤ 315 mm

Sub-structure Evaluation zones Displacement Velocity

µm (rms) mm/s (rms)

A
29 2.3
B
rigid 57 4.5
C
90 7.1
D
A
45 3.5
B
flexible 90 7.1
C
140 11
D

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Vibration Condition Evaluation
Evaluation According to ISO 10816 – Part 3 Group 2

• Medium size machines with nominal power from 15 kW to 300 kW;

electrical machines with shaft height 150 ≤ H ≤ 315 mm

Sub-structure Evaluation zones Displacement Velocity

µm (rms) mm/s (rms)

A 1.4
22
rigid
B
45 2.8
C
71 4.5
D

A 2.3
37
flexible B
71 4.5
C
113 7.1
D

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Vibration Condition Evaluation
Evaluation According to ISO 10816 – Part 3 Group 3

• Pumps with multi-vane impellers and separate drive (with radial, semi-radial
or axial flow) with nominal power above 15 kW

Sub-structure Evaluation zones Displacement Velocity

µm (rms) mm/s (rms)

A
18 2.3
B
rigid 36 4.5
C
56 7.1
D
A
28 3.5
B
flexible 56 7.1
C
90 11
D

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Vibration Condition Evaluation
Evaluation According to ISO 10816 – Part 3 Group 4

• Pumps with multi-vane impellers and integrated drive (with radial, semi-
radial or axial flow) with nominal power above 15 kW

Sub-structure Evaluation zones Displacement Velocity

µm (rms) mm/s (rms)

A
11 1.4
B
rigid 22 2.8
C
36 4.5
D
A
18 2.3
flexible
B
36 4.5
C
56 7.1
D

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Vibration Condition Evaluation
Evaluation According to ISO 7919

• Mechanical vibrations excluding repiprocating

machines. Measurement and ecaluation of shaft
vibrations
Part 1 General instructions
Part 2 Large, stationary steam turbine/generator sets
Part 3 Coupled industrial machines
Part 4 Gas turbines
Part 5 Machine sets in hydro-electric power and pumping plants

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Vibration Condition Evaluation
Evaluation According to ISO 7919

• Evaluation zones
Zone A
Vibrations in newly installed machines
Zone B
Machines may be operated continuously without restriction
Zone C
Machines may be operated only for a limited time
Zone D
Vibrations are excessive and may cause permanent damage to the
machines

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Vibration Condition Evaluation
Evaluation According to ISO 7919

• Guideline for measurement and evaluation

Criterion I
The relative shaft vibrations may not excees the
prescribed maximum values

Criterion II
The changes in the shaft vibrations, relative to an
initial level, may not exceed the prescribed maximum
values

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Vibration Condition Evaluation
Evaluation According to ISO 7919 – Part 2

• Large, stationary steam turbine/generator sets

Evaluation zone Shaft speed in rpm

1,500 1,800 3,000 3,600

Maximaler
maximum Schwingweg
relative shaft vibrationder Welle
displacement

A
100 90 80 75
B
200 185 165 150
C
320 290 260 240
D

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Vibration Condition Evaluation
Evaluation According to ISO 7919 – Part 3
450
400
• Coupled industrial machines

Peak-peak value of shaft vibration displacement

300

200
150
D
100
C

relative to the bearing, in mm

70
B
50
40
A
30

20

10
1 2 4 6 10 20 30
Shaft speed x 1,000 in rpm

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Vibration Condition Evaluation
Evaluation According to ISO 7919 – Part 4
450
400

Peak-peak value of shaft vibration displacement

• Gas turbines
300

200 D
150

relative to the bearing, in mm

100 C
70

50
B
40

30 A
20

10
3 4 6 8 10 20
Shaft speed x 1,000 in rpm

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Vibration Condition Evaluation
Evaluation According to ISO 7919 – Part 5
• Machine sets in hydro-electric and pump plants

Peak-peak value of vibration displacement

Evaluation zones, smax Evaluation zones, sp-p
Maximum shaft vibration displacement

500 1000
relative to the bearing, smax in µm

900

relative to the bearing, sp-p in µm

400 800
D 700 D
300 600

500
200
400
C
C
300

100
90
B 200
80 B
70
150
60
50
100
40
90
A 80 A
30 70
60
20 50
60 100 200 500 1000 1
2000 60 100 200 500 1000 2000
Max. shaft speed in rpm. Max. shaft speed in rpm.

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Vibration Basic Course

Vibration Fault Analysis
Condition Monitoring Division
Vibration Fault Analysis
Common Machinery Vibration Problems

• Unbalance
• Misalignment
• Eccentricity
• Bent Shaft
• Mechanical Looseness
• Shaft Crack
• Journal Bearing Faults
• Rolling Element Bearing Faults
• Rotor Rub
• Cavitations
• Electrical Motor Problems
• Gear Faults

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Vibration Fault Analysis
Unbalance

• When unbalance is dominant, radial vibration (horizontal and vertical) will

normally be quite much higher than axial
• Horizontal vibration is normally higher than vertical
• Always indicated by high vibration at 1x rpm (but 1x rpm is not always
unbalance!)
• Amplitude at 1x rpm will normally ≥ 80% of the overall amplitude when the
problem is limited to unbalance
• The effect on unbalance may sometimes be amplified by resonance
• Unbalance can be a great contributor to high looseness vibration

RPM
Radial

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Vibration Fault Analysis
Unbalance

• When unbalance dominates over other problems, there will normally be

about 90o (±30o) phase difference between horizontal and vertical
directions on the same bearing
• When significant unbalance exist, the horizontal phase difference between
outboard and inboard should be close to the vertical phase difference
• Unbalance rotors normally exhibit steady and repeatable phase in radial
directions

DIR. 1 2 3 4
A 60O 70O 60O 80O
H 30O 25O 30O 40O
V 120O 110O 120O 135O

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Vibration Fault Analysis
Static/Force Unbalance

• Approximately the same unbalance forces at 1x rpm are normally present

both on outboard and inboard bearing. However, horizontal and vertical
responses may differ depending on the support stiffness
• With pure force unbalance, outboard horizontal phase will equal to inboard
horizontal phase on the same shaft
• Likewise, outboard vertical phase should approximately equal to inboard
vertical phase on the same shaft
• The horizontal phase difference between outboard and inboard should
approximately equal the vertical phase difference between them

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Vibration Fault Analysis
Couple/Moment Unbalance

• In pure couple unbalance, the rotor is statically balance

• High vibration at 1x rpm on both outboard and inboard bearings, but it may
be higher on one bearing than on the other
• Substantial couple unbalance can sometimes generate high axial vibration
• The horizontal phase difference between outboard and inboard will
approximate 180o
• Similarly, vertical phase difference between outboard and inboard will
approximate 180o

DIR. 1 2 3 4
A 60O 70O 60O 80O
H 30O 210O 200O 180O
V 120O 295O 280O 300O
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Vibration Fault Analysis
Dynamic Unbalance

• Combination of static unbalance and couple unbalance

• High vibration at 1x rpm on both outboard and inboard bearings, but it may
be higher on one bearing than on the other
• Like static and couple unbalance, phase is still steady and repeatable when
dynamic unbalance dominates
• The horizontal phase difference between outboard and inboard could be
anything from 0o to 180o. The difference should approximately equal the
vertical phase difference

DIR. 1 2 3 4
A 60O 70O 60O 80O
H 30O 90O 80O 70O
V 120O 180O 170O 165O

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Vibration Fault Analysis
Overhung Unbalance

• Can generate large axial forces at 1x rpm which can cause axial vibration to
be equal or greater than radial
• Often generate high degree of couple unbalance in addition to static
unbalance; both of which must be corrected
• For pure unbalance of an overhung rotor, axial phase at bearing 1 will
approximately equal that at bearing 2 (±30o). The phase difference depends
on how dominant the unbalance problem is as compared to other such as
misalignment, resonance, etc
• Normally, overhung rotor unbalance can be corrected by first taking care of
the static unbalance component which would leave the remainder as couple
unbalance with phase difference approaching 180o. The couple component
would then require placement of correction weights in two planes 180o
opposite one another

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Vibration Fault Analysis
Eccentric Rotor

• Like unbalance, high radial (horizontal and vertical) vibration at 1x rpm. In

case of eccentric pulley, the largest vibration most often occurs in the
direction of belt tension at 1x rpm of the eccentric pulley
• May cause significantly higher vibration in one radial direction than in the
other (as does resonance and sometimes looseness as well)
• Attempts to balance eccentric rotor will often result in reducing vibration in
one direction, but increasing in the other radial direction
• Approximately 0o or 180o phase difference between horizontal and vertical
directions on the same bearing

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Vibration Fault Analysis
Misalignment

• Normally causes both high axial and radial vibration. However, it is not
always having high axial, especially when parallel offset dominates over
angular misalignment
• Generates higher than normal 2x rpm vibration which can act not only in
axial direction but also in radial
• If the misalignment becomes severe, can also cause large numbers of
harmonics which will make the spectrum appear like looseness problem
• For significant misalignment, radial (both horizontal and vertical) phase
differences will be either 0o or 180o (±30o) between inboard and outboard
bearing
• Most of the time, horizontal phase difference approaching 180o out of
phase compare with vertical phase difference

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Vibration Fault Analysis
Angular Misalignment

• High axial vibration, particularly at 1x, 2x (and 3x) rpm. One of this peaks
sometime dominates over the others
• Typically, amplitude of either 2x or 3x rpm reach approximately 30-50% of
1x rpm in axial direction
• Best indication is 180o phase difference across the coupling in axial direction

10

3.1
1

0.31

mm/s 1X 2X 3X

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Vibration Fault Analysis
Parallel Misalignment

• High radial vibration, particularly at 1x, 2x (and 3x) rpm. One of this peaks
sometime dominates over the others
• Typically, amplitude at 2x rpm reach approximately 50% of 1x rpm in radial
direction. Can exceed the 1x rpm if parallel misalignment becomes severe
• Best indication is 180o phase difference across the coupling in radial
(horizontal and vertical) direction

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Vibration Fault Analysis
Bearing Misalignment

• Considerable axial vibration at 1x (and 2x) rpm

• Axial phase at four points 90o apart each other will also shift 90o from one
point to the next
• Attempts to align the coupling or balance the rotor will not solve the
problem. The effected bearing must be removed and correctly installed
Point 1, 2, 3 and 4 are axial measurement, 90o apart each other
Cocked (misaligned) bearing will have axial phase e.g. as follow:
Axial 1 = 10o
BEARING
Axial 2 = 100o
SHAFT 1
Axial 3 = 190o
4
Axial 4 = 280o 2
3

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Vibration Fault Analysis
Bent Shaft

• Dominant vibration normally is at 1x rpm if bent near the shaft center

(indication like unbalance), and particularly at 2x rpm if bent near the
coupling (indication like misalignment)
• Axial phase difference between inboard and outboard bearing will approach
180o
• If the shaft is bowed through or very near the bearing, axial phase at four
points 90o apart each other will also shift 90o from one point to the next,
like cocked bearing

BEARING
SHAFT 1

4
2
3

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Vibration Fault Analysis
Mechanical Looseness

• Mechanical looseness always indicated by rising harmonics and sub-

harmonics
Shaft loose mm/s

10

3.1
1

0.31

.5X 1X 1.5X 2X 3X
mm/s
Bearing loose
10

3.1
1

0.31

.5X 1X 1.5X 2X 3X

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Vibration Fault Analysis
Rolling Element Bearing Faults

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Vibration Fault Analysis
Rolling Element Bearing Faults

• FTF = ½ [1 – (B/P) cos φ] Hz ≈ 0.41 rpm

• BPFO = ½ N [1 – (B/P) cos φ] Hz ≈ 0.41 N rpm
• BPFI = ½ N [1 + (B/P) cos φ] Hz ≈ 0.59 N rpm
• BSF = ½ (P/B) [1 – (B/P)2 cos2 φ] Hz ≈ 0.22 N rpm

• N: number of rolling element Hz = rpm/60

• B: rolling element diameter
• P: pitch diameter
• φ: contact angle

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Vibration Fault Analysis
Gear Faults

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Vibration Fault Analysis
Gear Faults

• Observe Gear Mesh Frequency harmonic and its sideband

• GMF = N1 x T1 = N2 x T2, N = rpm/60
• Gear natural frequency with sideband at 1x rpm indicates gear wear or
backlash, GMF decrease if load increase when the problem is backlash
• High GMF without high sideband doesn’t problem, it indicates tooth load
• High 2x rpm, 2x GMF with sideband at 2x rpm indicates gear misalignment
• Cracked/broken tooth is indicated in time waveform

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Vibration Fault Analysis
Motor Faults – Induction Motor

• Always use high resolution spectrum (3200 lines) to differentiate line

frequency from turning frequency
• 2x FL (100 Hz) indicates stator problem
• 2x FL with sideband at Pole Pass Frequency (FP) and 1x rpm with sideband at
FP indicates variable air gap
• FP = number of pole x slip frequency (low freq!)
• 1x rpm and its harmonic with sideband at FP indicates shorting ring or
lamination problem
• Rotor Bar Pass Frequency and its harmonic with sideband at 2x FL indicates
rotor bar problem
• RBPF = number of bars x turning frequency

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Vibration Fault Analysis
Motor Faults – Synchronous Motor

• Coil Pass Frequency with sideband at 1x rpm indicates stator coil problem
• CPF = number of pole x number of coil/pole x turning frequency
• Problems normally indicated at 1 kHz and above with sideband at 2x FL

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Vibration Fault Analysis
Motor Faults – DC Motor

• High SCR (3x or 6x FL) and 2x SCR indicates winding or grounding problem
• 1/3 and 2/3 SCR indicates firing problem, faulty SCR, loose connection

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Vibration Fault Analysis
Fan, Pump, Compressor, Turbine

• Very common fan fault is unbalance

• Common pump fault other than unbalance are
recirculation (low flow) and cavitation (low head)
• Compressor and turbine which in many case are using
journal bearing, will be best monitored using
displacement probe (relative shaft vibration instead of
absolute casing vibration). Normally shaft orbit and
bode/polar plot is monitored

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Vibration Fault Analysis
Fan, Pump, Compressor, Turbine
Recirculation

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Vibration Fault Analysis
Fan, Pump, Compressor, Turbine
Cavitation

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Vibration Fault Analysis
Natural Frequency, Resonance – Bump Test

• Bump = impact; forcing frequencies at broadband

• 800 or 1600 lines of resolution
• Several frequency spans
• Uniform window
• The concern is frequency, not amplitude
• Bump around
• 1 bump for each time

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