THE MACHINE VIBRATION ANALYSTS NEWSLETTER
FEATURED THIS ISSUE Featured Lesson
1
Pump, Fan, and Compressor Vibration
Featured Article
faults rather 4 Preventing than just detecting them;
the ultimate challenge for vibration analysts
Video
Animated Introduction 7 An to Vibration Analysis
SAVE THE DATE! Series 4 | Issue 2 | August 2017
AUSTRALIA | SEPTEMBER 5 - 7, 2017 S E E B A C K C O V E R F O R D E TA I L S
About Mobius Institute
IN THIS ISSUE
1
FEATURED LESSON
Pump, Fan, and Compressor Vibration
4
FEATURED ARTICLE
Preventing faults rather than just detecting them; the ultimate challenge for vibration analysts
MOBIUS INSTITUTE is a worldwide provider of Reliability Improvement, Condition Monitoring and Precision Maintenance education to industrial plant managers, reliability engineers and condition monitoring technicians, allowing plants to be successful in implementing Reliability Improvement programs through delivery of more easily understandable and comprehensive training of Reliability and Vibration Analysis via public, in-plant and online education programs. Mobius Institute Board of Certification is ISO 17024 and ISO 18436-1 accredited, and provides accredited vibration analyst certification according to ISO 18436-1 and ISO 18436-2.
Key Contacts at Mobius Institute Founder & CEO - Jason Tranter -
[email protected] Co-founder & CFO - Georgina Breedon -
[email protected] General Manager - Terry Blackman -
[email protected] Certification Manager - Roberta Clark -
[email protected] North America Business Manager - Bill Slonaker -
[email protected] Marketing & Communications Director - Dean Lofall -
[email protected] IMVAC Conference Director - Becky Partipilo -
[email protected]
7
VIDEO SPOTLIGHT
An Animated Introduction to Vibration Analysis
CONTRIBUTING AUTHOR Jason Tranter
8
SCHOLARSHIP NEWS
Q2 winners announced
9
VIBRATION ANALYST HALL OF FAME
Recognizing our Vibration Superheros
10
UPCOMING COURSES
12
Founder & CEO, Mobius Institute
Jason Tranter has been involved with condition monitoring since 1984. He is the founder and managing director of the Mobius Institute and the Mobius Institute Board of Certification. Mobius Institute is ISO-accredited to ISO 17024 and ISO 18436-1. Mobius has training centers in more than 50 countries and has trained over 22,000 people in a classroom setting and many thousands more via e-learning. Jason is the author of the majority of Mobius’ classroom material and the “iLearn” series of products, and is a member of ISO TC108/ SC5. After running a vibration consulting and software development company in Australia in the mid-’80s, Jason sold his business and moved to the United States as the product development manager at DLI Engineering (now Azima/DLI). Jason has delivered presentations, workshops and had articles published all over the world.
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FEATURED LESSON
FEATURED LESSON
Pump, Fan, and Compressor Vibration
Pumps, fans and compressors can all suffer from the classic fault conditions such as imbalance, misalignment, bearing faults, and looseness. However, some faults are unique to these components. There are many types of pumps in common use, and their vibration signatures vary over a wide range. When monitoring pump vibration, it is extremely important that the operating conditions are consistent from one measurement to the next to assure consistent vibration patterns. Suction pressure, discharge pressure, and especially air induction and cavitation will affect the vibration pattern greatly. Centrifugal pumps always have a prominent vibration component at the vane pass frequency, which is the number of impeller vanes times the RPM. If the amplitude increases significantly, it usually means an
VIBRATION MATTERS - AUGUST 2017
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FEATURED LESSON
FEATURED LESSON continued N
internal problem such as erosion of impellers or a flow related problem. Harmonics of vane pass are also common in such pumps. Forces are generated by the pressure variations as a rotating blade, vane, or lobe passes a stationary housing or component. The stationary component creates a non-uniform flow disturbance in the fluid or gas.
System Fluid Starvation Other faults include the impeller loose on the shaft and pump starvation. When the impeller is loose on the shaft, there will be vane pass frequency with sidebands of turning speed.
Blade Passing Frequency In its broadest sense, Blade Passing Frequency includes similar components such as vanes, lobes, and pistons. The forcing frequencies are: • Number of blades x turning speed • Number of vanes x turning speed
Pump starvation may look like imbalance as the flow into the volute is uneven. The time waveform would show distortion due to the flow being uneven. The distorted time waveform produces harmonics of turning speed.
Cavitation Cavitation normally creates random, higher frequency vibration or “noise”. It is often observed as a “hump” in the vibration spectrum raising the floor from about 15X to 35X.
• Number of lobes x turning speed • Number of pistons x turning speed Causes of high blade passing frequency are:
Cavitation normally indicates insufficient suction pressure or starvation - i.e. low inlet pressure. The liquid tends to vaporize while coming off the impeller creating vacuum bubbles that implode. The waveform can often sound like gravel in the pump.
• Rotor or housing eccentricity • Non-uniform variable pitch blades • Loose, bent, or misaligned housing diffuser vanes • Blade or vane wear (abrasion or cavitation) • Operation (improper performance parameters) • Improper damping settings • Dirty, damaged or missing filters
• Inlet or discharge line restrictions
VIBRATION MATTERS - AUGUST 2017
The data above is from a 20 hp centrifugal pump that has a
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FEATURED LESSON continued
cavitation problem. It sounds like it is pumping gravel. The time waveform is a very useful analysis tool, as the high frequency bursts of energy are often clearly visible - however, more time data (i.e. a longer record) than normal may be needed.
Harmonics Lobed blowers and screw compressors generate harmonics under normal conditions. Here is a typical example:
The spectrum reflects the impacting in the raised noise floor and mounds of energy under the peaks. The highest peak is at vane pass.
• Sullair Rotary Screw Compressor, 1650 CFM
Turbulence Turbulence in fans, pumps, and compressors is induced when the normal flow is restricted or impeded during operation. It shows up in spectral data as low frequency, broad peaks between 0.5 and 0.8 orders.
• Speed is 1780 CPM • 300 HP motor • Female rotor has 6 vanes and the male has 4 vanes.
t Causes of turbulence are: • Obstruction in air ducts or plumbing lines • Sharp radius turns in piping • Abrupt diameter changes in lines • Over capacity operation
VIBRATION MATTERS - AUGUST 2017
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FEATURED ARTICLE
Preventing faults rather than just detecting them; the ultimate challenge for vibration analysts by Jason Tranter, BE(Hons), CMRP, VA-IV
“Even though a good vibration analysis program can achieve considerable savings, many do not achieve their full potential.”
Founder & CEO of Mobius Institute Vibration analysts are a rare breed. From vibration readings taken on rotating machinery they can detect all manner of fault conditions. They can tell if the machine is misaligned, they can tell if a pump is cavitating, and they can even tell if there is damage on the inner race of a rolling element bearing. All of these skills are gained through extensive training and years of experience in the field. A successful vibration monitoring program can greatly reduce maintenance costs. Downtime can be reduced, secondary damage can be minimized, labor costs can be reduced, and safety can be improved. If faults are detected in the earliest stages, the maintenance can be planned to occur when it is most convenient to the plant. Even though a good vibration analysis program can achieve considerable savings, many do not achieve their full potential. Vibration analysis programs, and all other condition monitoring programs, are only there to detect faults that exist within the machine - they do not actually improve reliability. Sure, if you consider a reduction in catastrophic failures as an improvement of reliability, then vibration analysis programs do improve reliability. But a true measure of reliability improvement should be a reduction in the faults that develop in the machines. Vibration analysts shouldn’t detect misalignment that results from poor alignment practices. Vibration analysts shouldn’t detect cavitation. And vibration analysts shouldn’t detect faults in rolling element bearings - unless the bearing has been installed for a very long time. While there are a fault conditions that will develop over a long time due to normal ‘wear and tear’, many of the fault conditions develop because the machine was not operated correctly, installed correctly, lubricated correctly, aligned correctly, transported correctly, or because it was not ideally suited to the application. Rotating machinery, and their individual components, are all too often selected based on price and not reliability. Lifetime costs are not taken into consideration. Therefore, to achieve the greatest reduction in maintenance and operating costs, the vibration analyst’s job should not be limited to the detection of fault conditions. The vibration analyst should be involved with reliability improvement. Let’s explore some of the ways that the vibration analyst can help improve reliability.
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FEATURED ARTICLELESSON continued FEATURED
Initial design and purchasing policies
Field-balancing and shaft alignment
When a specification is put together for a new piece of equipment, achieving high reliability should be one of the key goals. The lifetime costs must be considered ahead of the upfront purchase price. Experience with similar equipment and the suppliers should be taken into consideration. Maintainability should be taken into consideration.
Many vibration analysts are involved with field-balancing and shaft-alignment. Balancing reduces rotating forces which can damage bearings and the machine structure. Likewise shaft alignment reduces the stress on bearings, couplings, and the shaft itself. Even if the vibration analyst does not perform the shaft alignment or balancing function, the analyst should take vibration readings before and after the work to ensure that the job is done correctly.
The vibration analyst should be consulted when rotating equipment is to be purchased. If the machine being considered has a history of reliability problems then it does not make sense to purchase that same type of machine again. In an ideal world, machinery with easy-to-access monitoring points would be selected, but that really is hoping for too much!
Acceptance testing There is often an assumption that components, lubricants and the machines themselves are in perfect condition when they are purchased. Sadly this is not always the case. Bearings may not be transported or stored correctly and may suffer from false-brinelling. Lubricants may not meet cleanliness standards. Rotating machinery may suffer from resonance and other conditions when operated under normal conditions. Too often rotating machinery are not designed with energy efficiency and reliability in mind; instead they are designed with purchase cost in mind. Acceptance testing provides a way to test that machines and components are in good condition before they are installed in the plant. Acceptance testing puts pressure on the supplier to make sure they are delivering the highest quality products. Acceptance testing guidelines can include specifications on a number of parameters, but from the vibration analysts perspective the key standard is to set vibration limits that may not be exceeded. Tests may be performed at the OEMs workshop or after being installed on-site. It is important the conditions for the test are clearly specified, including RPM, load, and mounting. Acceptance testing should not only be performed on new equipment, it should be performed when repair and overhaul work is performed. This can include motor rewinds, rotor balancing, and pump rebuilds. There are a number of ISO standards that provide guidelines for acceptable vibration limits when equipment is new or overhauled, and there are a number of specifications in the public domain.
It is important to set targets when performing shaft alignment and field balancing. It is not enough to simply perform the job and assume that because the vibration levels have been reduced that the job is good enough. Standards from the ISO, API, and the US Navy are readily accessible and provide an indication of balance quality. It is worth pointing out that while the G 6.3 standard is recommended in ISO 1940, G 1.0 should be the target if precision maintenance is your goal. The equivalent API standard is G 0.7. Rotating machinery OEMs will often provide shaft alignment tolerances, and the laser alignment manufacturers will also provide guidelines so that a precision alignment can be performed every time. One standard that should not be used is the specification provided with certain flexible couplings. These very loose specifications provide an indication of what the coupling may survive but they do not provide an indication of what is best for the long-term operation of the machine.
Resonance correction Resonance occurs when a machine generates vibration at a frequency close to a natural frequency of the rotor or structure. Resonance greatly amplifies the vibration amplitude; the high vibration amplitude reduces the life of the bearings and the machine structure. The vibration analyst can get involved in two ways. First the vibration analyst can identify the source of vibration that is exciting the natural frequency and seek to reduce that vibration amplitude. For example if there is unbalance which is exciting the natural frequency then one solution is to simply balance the machine. The second way that the vibration analyst can help is to perform tests that identify the natural frequencies and then propose modifications to the structure so that the natural
VIBRATION MATTERS - AUGUST 2017
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FEATURED ARTICLE continued
frequencies no longer correspond to the frequencies being generated by the machine. The most common situation is where the running speed of the machine corresponds with the natural frequency, however other sources of vibration such as the pump vane rate, blade passing frequencies and other can also excite natural frequencies. It may be necessary to increase the stiffness of the structure in order to increase the natural frequency so that it is no longer excited by the vibration generated by the machine. There are a number of ways to correct resonance; however that topic is beyond the scope of this article.
Root cause analysis Unbalance, misalignment, incorrect belt tension, poor lubrication practices, incorrect machine operation, and resonance are common root causes of failures in rotating machinery, however many others exist. Whenever the vibration analyst detects a fault in the machine, he or she should always attempt to determine the root cause. Once the root cause is identified measures should be taken so that root cause is eliminated. It is clever to be able to detect a bearing defect, but it is not very clever if the same bearing exhibits the same fault condition just months later. The vibration analyst will need to determine the most appropriate action that he or she can take at their place of work to avoid a repeat of the
fault. Craftspeople, equipment operators, and maintenance people can be sensitive to suggestions for improvements in their work. No one likes to have a finger pointed at them when there is an equipment failure. However, providing short training sessions that provide information about best practices and the benefits of improved reliability are typically accepted with enthusiasm. When people recognize that improvements to reliability are encouraged and supported by management, then a person’s pride and desire for safety and plant profitability will normally kick-in and these initiatives will be strongly supported.
Conclusion An effective vibration monitoring program will always be required, even when the best reliability improvement programs are well-established. Bearings still wear out, rotors become out of balance, and even the best trained craftspeople make mistakes. But utilizing vibration analysis skills to improve reliability should always be the goal of every vibration analyst.
t
The Vibration Matters Brain Teaser asks questions about topics taught in previous issues. Have a little fun, answer the question and once you do, you will see how others have answered too!
Q.
Generally, an induction motor having an uneven/eccentric air gap will produce what spectral characteristics?
A.
Click here to select your answer on the Mobius Institute website.
VIBRATION MATTERS - AUGUST 2017
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FEATURED VIDEO
An Animated Introduction to Vibration Analysis
Vibration analysis provides an extremely powerful opportunity to learn about the condition of rotating machinery – but only if you understand it and can use it properly. Learn more in our video.
Related Video
“Utilizing Vibration Analysis to Detect Gearbox Faults” In this Webinar we will summarize several techniques and use animations and software simulations to make them easier to understand. VIBRATION MATTERS - AUGUST 2017
THE VIBRATION ANALYST’S NEWSLETTER
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SCHOLARSHIP AWARDS
Vibration analysis is an important skill, but being a vibration analyst, with people counting on you to make timely, accurate diagnoses, is a demanding role. Education and accredited certification are key to success, and the IMVAC conferences enable analysts to further their knowledge and meet people who not everyone in the world has access to that training or the conference. While we try to minimize costs, for a whole variety of reasons those costs are too high for some people who desire to join our profession. Mobius Institute, in association with the IMVAC conference, would like to help twelve people each year to achieve Category II certification and benefit from the IMVAC conferences: General Awards (twelve recipients) • Mobius Institute Category I and Category II Vibration Analyst Training via Distance Learning • MIBoC Certification Examinations for Category I and Category II certification according to ISO 18436 • Access to IMVAC conference presentation and case study videos via online access Top Award (one recipient) • All expenses paid trip (registration, hotel and travel expenses) to attend an IMVAC conference of their choice
The Q3 scholarship is now accepting submissions. To learn more about the Mobius Scholarship program visit our website.
VIBRATION MATTERS - AUGUST 2017
The 2017 Q2 Scholarship Winners We were delighted by the incredible response to the scholarship offer, with submissions from over 256 prospective vibration analysts from more than 57 different countries. Though our selection process, we have selected the three most deserving recipients. Eric Anti Ofori, Takoradi, Ghana
“This scholarship is indeed a dream come true for me. I have harboured the dream of becoming a vibration analyst since the early days of my engineering career about 10 years ago. financial constraints truncated my dream half way. with no hope, Mobius has resurrected my dream with this scholarship award.” -Eric Anti Ofori, Ghana
Mahsa Yazdanian Asr, Karaj, Iran
“In fact, this is one of the best opportunities I have ever had in my life. This is really a turning point in my professions. It can also lead me to job promotion. I’m working with all my efforts in the field of condition monitoring at university and industry simultaneously.” -Mahsa Yazdanian Asr, Mapna Electric and Control Engineering and Manfacturing Co (MECO), Iran
Randall C. Smith, Friendswood, Texas, USA
“I really appreciate the scholarship offered by Mobius Institute. As an older mechanic/millwright I am finding it more difficult to find jobs partially because since almost all of my experience was with an oil company which made sure we knew our jobs but was not really worried about certifications. We did condition monitoring including vibration monitoring, oil analysis, temperature monitoring and pressure monitoring. The companies I talk to now would prefer an Associates degree or Certificate for any good maintenance and reliability job but when was on the job training. So now with this scholarship I will have something to add to my experience while job hunting.” -Randall C. Smith, USA THE VIBRATION ANALYST’S NEWSLETTER
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UPCOMING VIBRATION MOBIUS HALL COURSES OF FAME
Roenghai Chumai CAT IV
Certificate: M-6966-01 Exp: 27 June 2019 Location: Rayong, TH
João Pedro Pais CAT IV
Certificate: M-6970-01 Exp: 27 June 2019 Location: Banchory, UK
ISO Category IV Vibration Analysts are an elite group of specialists that carry the highest regard in the field of Condition Monitoring, at Mobius Institute we recognize them VIBRATION SUPERHEROS. VIBRATION SUPERHEROS are qualified to lead condition monitoring teams and have a deep understanding of machine dynamics and failure modes. Their knowledge and qualifications allow them to design tests to solve difficult problems and identify underlying issues to prevent reoccurrence. There are no rotating machines problems too difficult to solve.
Hossein Varvani Farahani CAT IV
Certificate: M-6975-01 Exp: 30 June 2019 Location: Arak, Markazi, IR
Amir Karam CAT IV
Certificate: M-6965-01 Exp: 5 August 2019 Location: Cairo, EG
Luca Amoroso CAT IV
Certificate: M-6972-01 Exp: 9 September 2019 Location: Desio, IT
Sascha Hein CAT IV
Mobius Institute would like congratulate all of our Vibration Superheros and take the opportunity recognize several of you in each issue of Vibration Matters. You can become a VIBRATION SUPERHERO TOO! Mobius Institute is holding three more CAT-IV courses (and exams) in 2017. To learn more about CAT-IV blended training click here. To see our 2017 schedule of courses, click here.
VIBRATION MATTERS - AUGUST 2017
Certificate: M-8301-01 Exp: 10 October 2019 Location: Ismaning, DE
Gary Behrens CAT IV
Certificate: M-6963-01 Exp: 10 December 2019 Location: Cambelltown, NSW, AU
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CAT - I
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VIBRATION MATTERS - JUNE 2017
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