CHAPTER 01: INTRODUCTION TO VIBRATION BASED

CONDITION MONITORING

Q.1. Explain vibration-based condition monitoring and fault diagnosis in

rotating machine.
Ans. Vibration-Based Condition Monitoring (VCBM):

Definition:

VCBM is a technique used to monitor the health of rotating machinery by analysing

vibration signals. Rotating machines such as motors, turbines, pumps, and
compressors generate vibrations due to various mechanical and operational
factors. Any deviation in vibration patterns can indicate potential faults.

Process of Vibration-Based Condition Monitoring:

1. Data Collection:
• Sensors (e.g., accelerometers, velocity transducers) are mounted on the
machine to collect vibration signals.
• The data is typically gathered in the time domain and can be converted to the
frequency domain using Fourier Transform.
2. Signal Processing:
• Techniques like Fast Fourier Transform (FFT), envelope detection, and time-
domain analysis are used to extract features from vibration signals.
3. Feature Extraction:
• Key features include amplitude, frequency, phase, and overall vibration levels.
4. Fault Identification:
• The extracted features are compared with known fault patterns to identify the
presence of anomalies.

Fault Diagnosis in Rotating Machines

Definition:

Fault diagnosis is the process of identifying the specific fault type, location, and
severity in a rotating machine using vibration data.

Common Faults Detected Through Vibration Analysis:

1. Imbalance:
• Cause: Uneven mass distribution in the rotating part.
• Vibration Signature: Increased vibration at 1x the rotational speed
(fundamental frequency).

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 2. Misalignment:
• Cause: Improper alignment of coupled shafts.
• Vibration Signature: High vibrations at 1x and 2x the rotational speed.
3. Bearing Faults:
• Cause: Wear, spalling, or defects in rolling elements.
• Vibration Signature: Specific defect frequencies such as ball pass frequency
outer race (BPFO) or ball pass frequency inner race (BPFI).
4. Gear Faults:
• Cause: Tooth wear, chipping, or misalignment in gears.
• Vibration Signature: Sidebands around gear mesh frequency.
5. Looseness:
• Cause: Loose components or inadequate mounting.
• Vibration Signature: Non-linear vibrations and harmonics.
6. Cavitation (for pumps):
• Cause: Formation and collapse of vapor bubbles.
• Vibration Signature: High-frequency noise with random patterns.

Example of Fault Diagnosis in Rotating Machinery:

Scenario: A centrifugal pump exhibits unusual vibration patterns.

• Observation: FFT analysis shows dominant peaks at the pump’s shaft frequency
and its harmonics.
• Diagnosis: Based on the vibration signature, it is concluded that the pump is
experiencing shaft misalignment.
• Action: Realignment of the pump and motor shafts resolves the issue.

Importance of VCBM and Fault Diagnosis

1. Improved Reliability: Early fault detection ensures uninterrupted operations.

2. Reduced Downtime: Identifying faults before catastrophic failure allows planned
maintenance.
3. Cost Savings: Prevents expensive repairs and replacements.
4. Safety: Avoids accidents caused by unexpected machine failures.

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Q.2. What are the advantages of vibration-based condition monitoring?
Write the steps involved in condition monitoring.
Ans. Advantages (Benefits) of Vibration-Based Condition Monitoring (VCBM):

1. Early Fault Detection:

• Identifies issues such as imbalance, misalignment, or bearing defects before
they cause catastrophic failure.
2. Minimized Downtime:
• Enables planned maintenance, reducing unplanned outages.
3. Cost Savings:
• Prevents expensive repairs and reduces the risk of secondary damage to other
components.
4. Non-Intrusive Method:
• Measurements are taken while the machine is operating, avoiding disruptions.
5. Improved Machine Reliability:
• Ensures consistent performance by addressing faults promptly.
6. Increased Safety:
• Reduces the likelihood of hazardous equipment failures, ensuring workplace
safety.
7. Energy Efficiency:
• Faulty machines often consume more energy; addressing faults improves
operational efficiency.
8. Comprehensive Diagnosis:
• Provides detailed insights into fault types and severity through spectral and
time-domain analysis.

Steps Involved in Condition Monitoring:

1. Identify Objectives:
• Define the goals of the monitoring program (e.g., improving reliability, reducing
costs).
• Identify critical machines that need monitoring based on their importance to
operations.
2. Sensor Selection and Installation:
• Choose appropriate sensors (e.g., accelerometers, velocity transducers)
based on machine type and operating conditions.
• Install sensors at strategic points, such as bearings, shafts, or casing.
3. Data Collection:
• Acquire vibration data during machine operation.
• Use data acquisition systems to record signals over time.
4. Data Preprocessing:

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 • Filter noise and remove irrelevant data.
• Normalize signals if necessary for consistency.
5. Signal Analysis:
• Perform time-domain, frequency-domain (e.g., FFT), or advanced methods
like wavelet analysis.
• Identify vibration signatures linked to specific faults.
6. Feature Extraction:
• Extract parameters like amplitude, frequency, phase, crest factor, and
kurtosis.
7. Fault Diagnosis:
• Compare vibration patterns with known fault signatures.
• Pinpoint the type, location, and severity of faults.
8. Prognosis (Optional):
• Predict remaining useful life (RUL) of components based on trends.
• Estimate time to failure for planning maintenance.
9. Report and Recommendations:
• Document findings, including identified faults and recommended actions.
• Suggest corrective measures like rebalancing, alignment, or part
replacement.
10. Continuous Monitoring:
• Implement a regular monitoring schedule to track machine health over time.
• Use automated systems for real-time monitoring where necessary.

Q.3. Define natural frequency and resonance.

Ans. Natural Frequency:

Definition:

The natural frequency of a system is the frequency at which it tends to vibrate when it is
disturbed and then left to vibrate freely without any external force acting on it.

Key Points:

1. It depends on the physical properties of the system, such as mass and stiffness.
2. Each structure or machine has one or more natural frequencies, depending on its
complexity.
3. In vibration systems, natural frequencies are determined using formulas derived
from Newtonian mechanics or modal analysis.

Example: A tuning fork has a natural frequency that causes it to emit a specific
musical note when struck.

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Resonance:

Definition:

Resonance occurs when a system is subjected to an external force that vibrates at a

frequency matching one of the system’s natural frequencies. This results in a large
increase in the amplitude of vibration.

Key Points:

1. Resonance amplifies vibrations, potentially causing damage or failure in

mechanical systems.
2. It is critical to avoid resonance in machinery by ensuring operational frequencies
do not align with natural frequencies.
3. Damping mechanisms can reduce the effects of resonance.

Example:

A bridge subjected to wind or pedestrian movement at its natural frequency can exhibit
resonance, as seen in the famous Tacoma Narrows Bridge collapse.

Q.4. Explain the concept prognosis and diagnosis in vibration-based condition

monitoring with example.

Ans. In vibration-based condition monitoring (VCBM), diagnosis and prognosis are two
essential concepts used for understanding the state of machinery and predicting its
future performance.

1. Diagnosis:

Definition: Diagnosis refers to identifying the current state of a machine by

analysing vibration signals. It focuses on detecting and locating faults or
anomalies.

Key Steps:

• Collect vibration data using sensors like accelerometers.

• Analyse the data using techniques like spectral analysis, waveform
analysis, or time-domain analysis.
• Identify fault signatures (e.g., imbalance, misalignment, bearing defects).

Example:

A motor shows increased vibration levels at 1x and 2x its rotational frequency.

Using spectral analysis, it is diagnosed that the motor has a misalignment issue.

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 2. Prognosis:

Definition: Prognosis involves predicting the future state of a machine based on

its current condition and operating trends. It estimates the remaining useful life
(RUL) or the time until a fault causes failure.

Key Steps:

• Use vibration data trends to predict wear or degradation.

• Apply predictive models (e.g., machine learning, physics-based models, or
statistical methods).
• Provide actionable insights for maintenance planning.

Example:

The vibration signal from a bearing exhibits a characteristic frequency indicating

spalling. Based on historical data and degradation trends, it is estimated that the
bearing will fail in 100 operating hours. This enables scheduling a replacement to
avoid unplanned downtime.

Comparison and Synergy:

Aspect Diagnosis Prognosis

Focus Current fault identification Future fault prediction
Outcome Fault type and severity Time to failure or RUL
Tools Vibration spectrum, fault Predictive models, trend
databases analysis
Action Immediate repairs or Maintenance scheduling
adjustments

Importance in VCBM:

Combining diagnosis and prognosis in VCBM ensures:

1. Reliable operations: Early fault detection avoids sudden failures.

2. Optimized maintenance: Predictive insights reduce unnecessary interventions.
3. Cost savings: Minimizes downtime and repair costs.

For instance, in a wind turbine, diagnosis can identify gear faults, while prognosis helps
predict when those faults will escalate, allowing planned maintenance during low wind
periods.

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Q.5. Explain importance of operating speed in machinery fault diagnosis using
vibration analysis? Also explain importance of sidebands.

Ans. Importance of Operating Speed in Machinery Fault Diagnosis Using Vibration

Analysis:

Operating speed, often expressed in revolutions per minute (RPM) or frequency (Hz),
plays a critical role in diagnosing machinery faults through vibration analysis. It serves as
a baseline for identifying and interpreting vibration patterns. Here’s why it is essential:

1. Identification of Fault Frequencies:

• Many machinery faults (e.g., imbalance, misalignment, or bearing defects)
manifest at specific frequencies related to the machine’s operating speed.
• These fault frequencies are calculated based on the machine’s rotational
speed and the geometry of components like gears and bearings.
• Example: An unbalanced rotor will exhibit a dominant vibration peak at the
operating speed (1× RPM). Misalignment might show vibrations at 1× and 2×
RPM.
2. Distinction Between Normal and Abnormal Conditions:
• Operating speed helps differentiate between normal vibrations and abnormal
signals caused by faults.
• For instance, gear mesh frequencies, which depend on the operating speed,
are compared to expected values to check for gear defects.
3. Avoiding Resonance:
• If a machine’s operating speed coincides with its natural frequency, resonance
can occur, amplifying vibrations and potentially causing severe damage.
• Vibration analysis ensures the machine is operated away from resonance
conditions.
4. Detection of Speed-Dependent Faults:
• Faults like rotor rub, imbalance, and aerodynamics issues are directly linked
to the operating speed.
• Monitoring vibration at varying speeds provides insights into these speed-
dependent issues.
• Example: An imbalance fault increases vibration proportionally with operating
speed, while bearing faults generate higher-frequency signals independent of
speed.
5. Accurate Trend Analysis:
• Changes in vibration amplitude or frequency relative to operating speed help
identify progressive faults.
• Speed normalization in vibration analysis ensures consistent fault diagnosis
over time.

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Importance of Sidebands in Vibration Analysis:

Sidebands are additional frequency components that appear around a primary

frequency in the vibration spectrum. They are crucial indicators of specific machinery
faults.

1. Indication of Modulation:
• Sidebands occur due to amplitude or frequency modulation caused by
interaction between machine components.
• For example, in gear systems, sidebands around the gear mesh frequency
indicate gear faults like wear or misalignment.
2. Diagnosis of Bearing Faults:
• Bearing defects often produce characteristic frequencies (e.g., ball pass
frequency, inner/outer race frequencies) with sidebands spaced at the shaft
rotational frequency.
• The presence of sidebands highlights the severity and progression of the fault.
3. Fault Identification in Gear Systems:
• Sidebands around gear mesh frequency indicate faults like tooth damage or
misalignment.
• The spacing of sidebands corresponds to the rotational speed of the faulty
gear or its driving component.
• Example: A chipped tooth in a gear will produce sidebands around the gear
mesh frequency at intervals of the shaft speed.
4. Indication of Looseness:
• Mechanical looseness generates sidebands at multiples of the fundamental
frequency.
• Sidebands in such cases indicate non-linear vibrations and impacts within the
system.
5. Early Detection of Complex Faults:
• Sidebands are often subtle and provide early signs of faults that might not yet
affect the main frequency components.
• They allow pre-emptive action before faults escalate.