VIBRATION
MONITROING
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What is vibration?
A machine, or part of machine, is said to vibrate
if it moves back and forth with respect to its
position of rest.
There are many ways to illustrate vibration. One
example is the Guittar string. When it is touched,
it will start to vibrate and produce a sound
because it will bring the air surrounding it into
vibration. Every sound we hear is nothing but air
vibration. Vibration is caused by a force that is
applied to the object.
One of the best examples to explain
vibration is a simple spring-mass system
as shown.
HISTORY
In the early stages of steam turbine
development, manufacturers already realized
that high vibration levels indicated a malfunction
of the machine. They would either listen to the
machine’s sound with a stethoscope or feel
vibration with their fingers and then decide
whether the machine had acceptable vibration
levels.
These methods, however, were not sufficiently
sensitive because one person would sense more
vibration than other.
Vibration Sensing By hand
Vibration Sensing By Stethoscope
Common sources of machine
Vibration
looseness
Unbalance shaft
Misalignment
Bearing instability
Rubbing
Oil whip
cavitations
Units of Vibration
Eddy current probe / proximity probe
It is measured in peak to peak and usually it is
written as p-p .
Its units are mils or microns.
1mil = 1/1000 inch = 0.001 inch
1 micron = 1/1000 mm = 0.001 mm
Velocity probe.
Velocity measure how much the displacement is
changing over a period of time.
The units of measure are inch per second or
millimeter per second.
It is measure in peak only. For example
40 micron/sec peak
Acceleration probe.
Acceleration is defined as rate of change of the
velocity and is measured in g’s of acceleration
relative to the acceleration of gravity.
At sea level, 1.0 g equals 32.2 ft/sec/sec or
386.087 in/sec/sec .
Acceleration is greatest where velocity is at a
minimum.
Two Types of Methods we use for Vibration.
1. Non Contact Method
Proximity probe
2. Contact Method
Velocity probe
Accelerometer
PROXIMITY PROB
Non contact method.
Different companies use different types of
transducer such as
Eddy current
Laser
Capacitance
Radar
Shape of proximity probe
Working principle
The eddy current probe basically consists of a
coil embedded in a tip of Ryton. Ryton is a
thermoplastic material with outstanding Thermal
stability, Mechanical strength and Chemical
resistance.
The coil of the probe is supplied with an RF
signal, generated by an oscillator operating at 2
MHZ.
Basic Transducer + Probe Working
If a conductive material is brought with in
the electromagnetic field of the probe,
eddy currents will be generated in the
material. Since the coil inductance will
change with variations in distance
between coil and observed surface.
The oscillator, detector, linearization and
amplifier electronics are all built into one
housing called the driver. this driver
receives a DC supply voltage of -18 to -24
volts and gives an output signal.
Since probe and extension cables are part
of the oscillator circuit, they have a fixed,
calibration length, slight changes, for example
replacing a connector, do not affect calibration,
the cable length should not be changed more
then a few inches because this will lead to
(small) calibration errors.
For vibration measurement the AC
component of the driver out put signal is
measured, for position measurements the DC
component is measured.
Proximitor + Probe + Extension
cable
Total length will be written at the proximitor or it
can be noted from the model no. of the
proximitor.
Suppose 5 miter = 0.5m + 4.5m = 5 m
or 1.0m + 4.0m = 5m
Same for 9 miter = 0.5m + 8.5m = 9m
or 1.0m + 8.0m = 9m
Eddy current probe Advantages
Low frequency response.
Can measure relative displacement.
Useful as a key phasor for dynamic balancing
& analysis.
Reliable if properly installed and maintained.
Eddy current probe Disadvantages
Difficult to install.
Practical limits of high frequency
displacement measurement.
Calibration dependent on shaft material.
Shaft run out / glitch produces false
signals.
Coding of proximity sensor
Part no –02 –12 –10 –02
02 Unthreaded length
12 Total length
10 One meter total length
02 BNC Connector
Coding of extension cable
21747 – 085 -00
040 4 METER LENGTH
045 4.5 METER LENGTH
080 8 METER LENGTH
085 8.5 METER LENGTH
00 WITHOUT ARMOURED
01 WITH ARMOURED
Coding of proximitor
18745 - 01 5 meter length and for
maximum ambient temperature = 80 °C
18745 – 02 9 meter length and for
maximum ambient temperature = 80 °C
18745 - 03 5 meter length and for
- 55 to 100 °C ambient temperature.
18745 - 04 9 meter length and for
- 55 to 100 °C ambient temperature.
Proximitor Name Plate
5 mm Proximitor
VT (-18 to -24 VDC)
Probe Dia. 5 mm (0.200 in)
Cable length 5 M (16.4 FT)
COM
Scale Factor 200 Mv / Mil (8 volt / mm)
Temperature Range -55 to 100 C
OUT PUT
OBS. MATL. AISI 4140
Catalog No. 18745-03
Mounting of Probes for Radial Vibration
THRUST MEASURMENT
Proximity probe method
Probe + extension cable + proximitor is used to
measure the thrust of any machine.
Suppose mechanical float of the machine (shaft)
is 0.30 mm.
Machinery crew set the shaft at center of its total
float. In this case they will set the shaft at
0.15mm. it means there will be a margin of
movement of the shaft at both ends.
Gap voltages of the probe will be set at 10.30
volts. So that the indicator of the monitor should
be at zero (middle)
Machinery crew will move the shaft to and fro
and the indication of control room indicator
should match with the dial indicator reading of
machinery.
Suppose the gap voltages during running the
machine at XT is 9.5 volts.
We know that the probe was set at 10.30 volts.
We also know that proximitor characteristics are
8 volts/mm or 200 mv /mil.
So 10.30-9.5 = 0.8 volts
8 volts = 1mm
0.8 / 8 = 0.1 mm
So 0.1mm will be displacement of the shaft
indicated at monitor and its direction will be
normal side.
Q2 volts are 11.75
11.75 - 10.30 = 1.45 volts
1.45 / 8 = 0.18 mm
The location of shaft will be at counter
side of the monitor.
Mounting of Probes for Axial Thrust Position
Selection of Probe
Shaft material
write on proximetor what AISI 4140 -8.00 v
is observed material,
normally write 304
Stainless -13.00 v
AISI 4140 Steel
Aluminum -15.50v
AISI= American iron & Copper -17.00v
steel Institute.
4140= Alloy Steel
Temperature
Due to change temperature range shift problem
found
Cone Effect
Se nso r tip 45 a ng le
Ma g ne tic fie ld
Senso r Tip
Bla nk sp a ce
2 x Tip Dia
Se nso r Tip
Bla nk sp a c e
45
Cross coupling / cross talk
1 inc h
Proper fixing
Distance between sensor & bearing
Radial vibration = max 6 inch Be a ring Se nso r
Sha ft
6 inc h
Thrust = max 12 inch
Be aring Senso r
Shaft
12 inch
Proper routing
Proper fix
No sharp bend
Connection must outside
Junction box
Tag
Proper connection
Checking of vibration instrument
Looseness
Rust
Physical condition
Oil / moisture
Grounding
Resistance
Sensor resistance = 4 to 5 ohm
Extension cable 4 & 4.5m = 3 to 4 ohm
Extension cable 8 & 8.5 m = 6 to 7 ohm
Ageing
Cross checking
Vibration simulator ( TK_3)
Velocity probe
The velocity probe is the commonly used pick up
for measuring bearing housing vibration .
This is contact method
It consists of a magnet, suspended by spring,
that can move with in a coil.
Above a certain frequency the magnet remains
at rest while the coil vibrates along with the pick-
up housing that is mounted on the vibrating
subject.
Since the coil moves with respect to the magnet,
a voltage is induced in the coil and this voltage is
proportional to the vibration velocity.
The frequency range of a velocity probe depends
on the springs and the mass of the seismic
element (magnet)
For most industrial types the range is some
where between 20 Hz to 1500 Hz.
Acceleration
Acceleration is defined as rate of
change of the velocity and is measured
in g’s of acceleration relative to the
acceleration of gravity.
At sea level, 1.0 g equals 32.2 ft/sec2
which equals 386.087 in/sec/sec or
9806.65 mm/sec/sec.
Acceleration is greatest where velocity
is at a minimum.
Piezoelectric Accelerometer
Piezoelectric material (sensing element) is
placed under load using a mass.
As machine vibrates, crystal is squeezed or
released.
Charge out put is proportional to the force.
Electronics convert charge output into voltage
out put.
Electrostatic Charge
The shaft of a rotating machine ideally should
have no voltage end to end or shaft to ground.
However, such voltages do exist on almost all
shafts due either to electrostatic charge build up
or residual magnetism.
Electrostatic charge via bearing is just like a
spark plug.
When there are voltages at shaft or there exists
residual magnetism, then there will be false
indication of vibration.
This indication is called electrical run out due to
Residual Magnetism / Electrostatic Charge.
Maintaining shaft voltage below one(1) volt on all
bearings should be considered a requirement for
preventing shaft current damaged to bearings,
gears etc.
The common practice of grounding the
shaft voltages with spring loaded carbon
rods or brushes composed of Graphite,
Composite, Babbitt or Copper straps.
Now a days a continues monitoring of
electrostatic charge is also being carried
out for providing early warning.
Rod Drop
Rod Drop is used to measure the down ward
trends of a connecting rod of Reciprocating
compressors.
But actually, indirectly we are monitoring
wear and tare of Rider Rings or Rider Bands
of reciprocating compressors' piston.
A proximity probe is installed vertically
above or below of Connecting Rod.
During operation Rod tends to move
downwards due to wearing of Rider
Rings, rod drop probe senses this
deviation at Rod and an early warning
receives for handling the situation.
The control room monitor’s scale is
designed in such a manner that it
directly indicated that trend of Rod
movement in the sense of mm.
Pneumatic Rod Drop Sensor (Alarm)
Common Mistakes
Tagging
No proper record maintain
Sealing
• Questions & Answers
