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TX5600 Vibration
Contents
Introduction 4 4.2 Sensitivity Range of dc
1. The Nature of Vibration 5 Vibration Sensors 23
1.1 Vibration Frequency 6 4.3 Frequency Range 24
1.2 Vibration Amplitude 7 4.4 Temperature Range 24
1.3 Vibration Phase 9 4.5 Mounting the Sensor 25
1.4 Vibration Spectrum 10 4.6 Where to Mount the Sensor 29
1.5 Vibration Parameter 4.7 Connecting the Sensor 31
Conversion 10 4.8 Monitoring Equipment 33
2. Using Vibration to Evaluate 5. Typical Vibration
Machine Condition 12 Monitoring Applications 40
2.1 When to use Displacement, 5.1 Underground Booster Fan
Velocity or Acceleration 12 Monitoring Utilising a
2.2 Classification of Vibration Programmable Sensor
Severity 14 Controller and the TX5633
2.3 Monitoring Acceleration 15 Vibration Sensor 40
2.4 Monitoring Velocity 15 5.2 Pump Monitoring 42
3. Methods of Vibration 5.3 Vibration Monitoring in
Monitoring 16 Hazardous Areas 45
3.1 Piezo-electric 5.4 Screening and Bunker
Accelerometers 16 Outfeed Monitoring 46
3.2 Piezo-resistive 5.5 Conveyor Drive Monitoring 47
Accelerometers 17 6. Interpreting Vibration
3.3 Eddy Current Probes 17 Data 49
3.4 Contact Displacement 6.1 Imbalance 51
Sensor 18 6.2 Gearmesh Problems 51
3.5 Industrial Applications 18 6.3 Bearing Breakdown 52
4. Determining the Right Disclaimers 53
Method 23 Trademarks 53
4.1 Sensitivity Range of ac Output Contact Details 53
Accelerometers 23 Document History 53
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Introduction
All machines and moving mechanical devices generate a wide spectrum of
vibration in normal use. The frequency and magnitude of vibration generated by
each component part of a machine varies greatly, and the characteristics of each
vibration signature changes further as a machine ages and deteriorates, resulting in
additional mechanical stresses.
Because of the wide and variable nature of vibration there is no standard solution
to the best method of condition monitoring. The aim of this handbook is to set
out a basic understanding about the cause and effects of vibration, and how to
use this information to determine the best methods of monitoring for a particular
application. Advise and guidance is also given about the various analytical methods
that can be exploited for optimal performance of a monitoring system.
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1. Frequency How many times does the machine or structure vibrate per minute
or per second?
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1.1 Vibration Frequency
Frequency can be calculated from a displacement waveform, by measuring the
time period (T) of one cycle and converting this to determine the frequency Hz. This
is an example of a time waveform which plots vibration amplitude against time.
Checkpoint
As the waveform is a truly sinusoidal direct comparisons can be made between
its peak-to-peak and RMS amplitudes, see Section 1.5.
Time waveforms are an excellent analytical tool to use when analysing gearboxes.
The sensor can be attached close to the input or the output shaft bearing and is
capable of revealing broken or chipped gear teeth on each revolution of the shaft or
gearwheel.
The illustration above shows a time waveform, showing the repeated impact of a
broken tooth.
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The same data can be presented on a frequency baseline to analyse the fault at the
rotational speed of the shaft or gearwheel.
Imbalance, misalignment, bent shaft, eccentric rotor, and other problems will often
produce a similar response in the frequency domain.
Time waveforms are particularly useful for low-speed shafts and gears, or
mechanical components that oscillate backwards and forwards. They are often the
only analytical tool which can be effectively used at lower rotational speeds or cycle
times.
1.2.1 Displacement
Displacement is a measure of the total travel of a measurement point, between
the two extremities of vibration and is usually expressed as a distance in microns.
When a machine is being subjected to excessive dynamic stress at very low
frequencies, displacement may be a good indicator of vibration severity since the
machine or structure, may be flexing too much, being subjected to impacts, or
simply being flexed too far.
1.2.2 Velocity
The velocity of vibration is a measure of the speed at which a mass is moving or
vibrating during its oscillations, the faster a machine flexes, the sooner it will fail in
fatigue. Vibration velocity is directly related to stress fatigue.
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When an oscillating mass is suspended from a spring the velocity of the mass
reaches its maximum value, or peak, at the mid point, the point at which the mass
is fully accelerated (acceleration is zero). It now begins to decelerate in the second
half of the cycle. Velocity is expressed as millimetres per second (mm/sec).
Checkpoint
In reality, vibration response is not usually a pure sine wave and an analyser is
invariably used to capture peak velocity.
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The greater the rate of change of velocity, the greater will be the forces and
stresses on the machine due to the higher acceleration. At high frequencies, the
excessive force can reach a point where the bearing lubrication can break down
allowing the metal surfaces of bearings to come into contact, potentially causing
catastrophic failures. These forces are directly proportional to acceleration (force =
mass x acceleration) and acceleration mode is the parameter most often employed
for machine protection.
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1.4 Vibration Spectrum
This frequency domain presentation of a time waveform is called a spectrum
analysis and is sometimes referred to as a vibration signature.
Electronics or processing software, can also convert between RMS (root mean
square), peak and peak-to-peak. The illustration below shows the relationship
between RMS, peak and peak-to-peak, for a purely sinusoidal waveform.
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TX5600 Handbook - Vibration
Most vibration waveforms are not sinusoidal in practice and peak and peak-to-peak
readings become less useful and RMS assessment is most often used.
RMS amplitude gives a more accurate representation of the energy within the
vibration, and hence the force that will be exerted.
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2. Using Vibration to Evaluate Machine Condition
The causes of vibration in rotating machinery are numerous. Some may simply
originate from machine set-up problems:
Imbalance of system
Misalignment of shafts
Bent or distorted shafts
Loose mechanical components
Ineffective or inadequate mounting structures
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Vibration severity categories expressed in terms of velocity, are defined for various
combinations of displacement and frequency.
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2.2 Classification of Vibration Severity
The standard general vibration severity chart is used to assess machine condition.
However this is intended to be used as a guide and not an absolute reference. The
standard of installation of the equipment and the general maintenance of it will
have a significant effect on the vibration levels seen.
Although the chart can be used as a general indication, trending of the vibration
levels against time will give a more accurate indication of the change in condition of
the machine. On fixed monitoring equipment, warning and alarm levels can be set
to be within the Good condition zone.
Class I: Individual parts of engines and machines, integrally connected with the
complete machine
Class III: Large prime movers and other large machines with rotating masses
mounted on rigid and heavy foundations up to about 300KW output
Class IV: Large prime movers and other large machines or turbines with
rotating masses mounted on foundations which are relatively soft
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3. Methods of Vibration Monitoring
A sensing element, mounted directly on to the machine, generates an output signal
that is proportional to the amplitude and frequency present in the machine. The
output signal format will be dependent upon the type of sensor being used.
This robust device has no moving parts and offers long term stability and reliability.
It has very wide frequency and dynamic ranges and the output signals can be
electronically integrated to give velocity and displacement values. Accelerometers
tend to be a more economical solution than the alternative devices and are available
for a wider range of arduous applications eg. high temperature environments,
submersible operation and high tolerance of corrosive media.
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3.4 Contact Displacement Sensor
There are a number of different types of contact displacement sensors. The most
commonly used version being the LVDT type.
The use of this type of sensor, is usually limited to specialist applications, and
relatively low vibration frequencies where direct contact with the surface being
monitored can be accommodated.
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If a second higher frequency band is also defined, then accurate data relating
to bearing condition can be monitored or trended to give advanced warning of
impending failure as a result of a worn or cracked bearing.
This method of vibration monitoring provides very accurate condition data about
specific parts of the machine, particularly when it is used in conjunction with
monitoring devices that can effectively analyse the data.
This range of vibration sensors is available with an ac output voltage compliant with
industry standard ICP interface. This provides for precision vibration measurement
for machine condition monitoring.
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Technical Details
Order Reference
Vibration Sensor - ac
Intrinsically Safe
Group I
TX5633
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Sensors for use on low speed machines, up to about 1 kHz, are calibrated in terms
of acceleration in a choice of measuring ranges from 2 g up to 100 g. Higher speed
machines in the 1 kHz to 10 kHz band are best assessed using sensors calibrated in
terms of velocity and there is a choice of ranges to suit various applications from
0 up to 100 mm/sec.
This type of sensor will accurately monitor the mean level of vibration across the
complete frequency spectrum and is very easy to interface with standard industrial
control loops. Any general deterioration of the machine condition will show up as a
general and overall increase in the level of vibration and this can be used for display
purposes or to operate alarm warnings and control devices. This particular sensor
is equally useful for indicating that a machine is actually running as it should be. For
example, vibration will be absent on a vibrating screen that has failed, so an alarm
warning can be initiated.
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Technical Details
Order Reference
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To take the example of a sensor that has a sensitivity of 100 mV/g, this means that
if 0.1 g is being measured by the sensor at a particular frequency, it would give an
ac output signal of: 0.1 x 100 = 10 mV. The appropriate full scale output range can
therefore be selected to match the input range of the monitoring equipment being
used. However, the severity of vibration is also a function of the frequency and
this factor should be carefully analysed in conjunction with the standard vibration
severity tables.
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4.3 Frequency Range
The frequency range specified for a vibration sensor is the frequency band over
which the sensor can effectively operate, and still provide a consistent output
signal. It is important to ensure that the operating frequency range of the machine
being monitored falls within the capability of the sensor.
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There are five commonly used sensor mounting methods and each one has a
maximum operating frequency that can be monitored.
Each mounting method also has its own resonant frequency and working in this
envelope of vibration should be avoided for best accuracy of response.
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4.5.1 Stud Mount
Stud mounting is used for permanently mounted sensor applications. Sometimes,
an adhesive will be used in combination with mounting thread to prevent the
sensor from losing its torsion under vibration conditions. Stud mounting is not
always practical for all applications, but it is the preferred method.
In order for the vibration sensor to reproduce precisely the vibration generated by
the machine under surveillance, it is imperative that its mounting face, in effect,
becomes a solid part of the structure. The sensor mounting face should see a flat
surface at the machine interface, any surface irregularities will compromise the
correct transmission of vibration.
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4.5.4 Handheld
This is the least acceptable method of mounting and is only really usable on
vibration frequencies below 1 kHz.
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4.5.5 Adhesive Mount
Adhesive mounts should be utilised as an alternative to stud mounting where a
stud cannot be fitted. Great care should be taken in preparing the surface when
using an adhesive, to ensure a permanent bond, because a bad joint will work loose
over a period of time.
The type of adhesive must be appropriate for the materials and the environment
in which it is to be used. The adhesive must also provide a rigid base. Soft set
adhesive will cause the higher frequencies to be absorbed.
4.5.6 Wiring
It is also recommended that the sensor cable is looped and then tied with a cable
tie to the main body in order to avoid excessive wear.
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When monitoring bearings, the sensor should be located as close to the source
of vibration as possible. This should be within the load zone of the bearing and is
particularly important where high frequency components of vibration are being
monitored.
The sensor should be mounted such that the sensing axis of the sensor passes
through the centre of the shaft and as close as possible to the shaft centre line.
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Fitting the sensor to one of the mounting feet of the machine will generally give
best results for axial vibration measurement if locations near to the rotating shaft
are inaccessible.
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It is recommended that the cable is looped where possible, and secured to the
sensor. This also avoids excessive wear and stress at the cable/sensor junction.
The cable can be terminated at a local junction box or sensor versions are available
with an integral plug and socket connector.
In order to avoid electrical pickup through the case of the sensor from the machine
being monitored, the machine should be properly earthed in compliance with local
regulations. If a good earth is not possible, the sensor and the cable overbraid
should be electrically isolated from the machine.
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The screen of the cable should be connected to earth at the monitoring equipment.
It should not be earthed at the motor. The cable overbraid should be left
unconnected.
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The data presented by the vibration sensors falls into two basic categories:
Each type of sensor will require an appropriate monitoring system for optimum
performance, and power to drive the sensor will be provided by the selected
control and monitoring unit.
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4.8.1 Programmable Trip Amplifier
These instruments can be used to provide a readout of vibration level and provide a
relay output contact, to alarm when levels exceed a pre-determined value.
There are versions to accept the ac signal from vibration sensors as well as the
conditioned output from 4 to 20mA sensors.
Total programming versatility in a single unit with direct fingertip selection of all
input and output control and display functions.
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Technical Details
Order Reference
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4.8.2 Programmable Trip Amplifier
Monitoring up to eight channels of vibration or a combination of condition
monitoring sensors. Datalogging and communication facilities allow for trending of
vibration. This simplifies monitoring of machine deterioration.
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Technical Details
Order Reference
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4.8.3 Distributed Monitoring
Multi channel distributed condition monitoring across a wide area network with
SCADA base station.
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This service can often form an important part of an on going structured preventative
maintenance programme.
However, due to cost, these instruments are rarely used for fixed installations. They
are usually used as portable instruments to diagnose problems found by overall
vibration level analysis instruments.
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5. Typical Vibration Monitoring Applications
5.1 Underground Booster Fan Monitoring Utilising a
Programmable Sensor Controller and the TX5633
Vibration Sensor
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In the illustration above each sensor signal feeds two independent input channels
on the controller. One channel monitors velocity (in mm/s) in the frequency range
10 to 500 Hz. The second channel is configured to monitor acceleration in the
frequency range 1 kHz to 20 kHz.
After the fan has been given time to run in, the vibration levels on each channel
should be monitored using an FFT analyser to ensure that there are no vibration
levels of concern.
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Velocity is used to monitor out-of-balance on the fan. This can be due to a number
of causes:
Misalignment of the shaft
Imbalance of the blades
Dust build-up on the blades
Chipped or broken blades
By looking at the trend of velocity and acceleration, the deterioration of the fan,
especially with respect to its bearings, can be monitored.
As well as monitoring excess vibration levels, the sensors will confirm that the
fan is running. A moderate level of vibration, indicates a healthy fan, running at its
normal speed. Lack of vibration would indicate a signal fail, or stationary fan.
In this application, two TX5633 sensors are mounted on the outlet end of the
pump, one vertical and one horizontal, to monitor: out-of-alignment, mounting
movement or loose fixings.
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The TX5633 sensors are connected to two channels of the Programmable Sensor
Controller which is set-up to monitor velocity in the range 10 to 500 Hz. The pump
is rotating at 3000 rpm giving a fundamental frequency of 50 Hz.
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As the Programmable Sensor Controller has spare channels available, temperature
and pressure monitoring on the pump can easily be accommodated using simple
PT100 probes and pressure sensors.
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In order to connect to the sensors in the hazardous area, zener safety barriers or
isolators need to be used between the sensors and the monitoring equipment. The
diagrams below give typical barrier and isolator options.
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5.4 Screening and Bunker Outfeed Monitoring
Vibratory screens are used for the grading of product in many mining and quarrying
applications. Product is introduced onto a vibrating sieve and small product passes
through whilst large product is screened to the next stage.
Vibrating pans are used on the outfeed to ensure that product does not block the
outfeed chutes.
A Trolex TX5630 Vibration Sensor mounted on the vibratory screen, can monitor the
operation and condition of the screen, when connected to a Programmable Sensor
Controller. Upper and Lower alarms can monitor that the screen is running correctly
and that vibration levels are not excessive. By trending vibration levels, deterioration
in the condition of the screen and its mounts can be monitored.
Similarly, the vibrating pans on the outfeed can be monitored for both operation and
excessive wear.
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The following diagram shows how the vibration sensors and temperature sensors
connected to a Programmable Sensor Controller and how this could be used to
disable the conveyor under high temperature conditions or excessive vibration.
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NAMUR sensors can be used to indicate conveyor speed and belt slip, by
monitoring the speed of both the motor and an idler wheel. If the temperature
inputs are programmed to latch one of the output relays when over temperature
occurs, the output relay could be interlocked with the conveyor stop circuitry to
lockout the conveyor. The latched relay would then have to be manually reset before
attempting to restart the machine.
An input from the conveyor drive contactor can give confirmation that the conveyor
is running.
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Ventilation fans are used in critical areas such as underground mining and
tunnelling, where natural ventilation is not sufficient to either dilute noxious/
explosive gases or to ensure a sufficient supply of oxygen.
Although these areas are not always as discreetly defined as shown here, they
have been separated for the purposes of this example.
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6.1 Imbalance
Imbalance occurs because the machine is not perfectly balanced about
the shaft centre line. This can be caused during manufacture, installation
or during operation (eg. debris build-up on a fan blade).
Imbalance will occur at the rotational frequency of the fan. So on a fan rotating at
1500 rpm, imbalance will occur at 25 Hz. As the imbalance increases, it will be seen
as increase in the vibration signal at 25 Hz. This will require a monitoring instrument
capable of displaying the signal in the frequency domain
(eg. FFT analyser).
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6.3 Bearing Breakdown
Bearing noise, due to imperfections in the bearing, will start at high
frequency (>1 kHz). Bearing deterioration can be caused by:
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Disclaimers
The information provided in this document contains general descriptions and
technical characteristics of the performance of the product. It is not intended as
a substitute for and is not to be used for determining suitability or reliability of
this product for specific user applications. It is the duty of any user or installer to
perform the appropriate and complete risk analysis, evaluation and testing of the
products with respect to the relevant specific application or use. Trolex shall not be
responsible or liable for misuse of the information contained herein. If you have any
suggestions for improvements or amendments, or find errors in this publication,
please notify us at marketing@trolex.com.
All pertinent state, regional, and local safety regulations must be observed
when installing and using this product. For reasons of safety and to help ensure
compliance with documented system data, only Trolex or its affiliates should
perform repairs to components.
When devices are used for applications with technical safety requirements, the
relevant instructions must be followed.
Trademarks
2014 Trolex Limited.
Trolex is a registered trademark of Trolex Limited. The use of all trademarks in this
document is acknowledged.
Document History
Issue 01 19 June 2014 Original publication of this document
Contact Details
Trolex Ltd, Newby Road, Hazel Grove, Stockport, Cheshire, SK7 5DY, UK
+44 (0) 161 483 1435 sales@trolex.com
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