Table Of ContentHBK|w:155.575mm;h:234.95mm;sp:21mm|Design:s45|RAPSticket:239891|Created:14:2418/12/19
Vibration-basedconditionmonitoring(VCM)isawell-acceptedapproachinindustriesforearly JyIN
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detection of any defect, thereby triggering the maintenance process and ultimately reducing tD
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overheadsand plant downtime. Anumber of vibrationinstruments, data analyzerand related KU
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hardware and software codes are developed to meet the industry requirements. This book ST
inR
aims to address issues faced by VCM professionals, such as frequency range estimation for hI
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vibration measurements, sensors, data collection and data analyzer, including related L
parameters which are explained through step-by-step approaches. Each chapter is written in A
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the tutorial style with experimental and/or industrial examples for clear understanding.
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Jyoti K. Sinha (BSc (Mech), MTech (Aero), PhD, CEng, FIMechE) is Programme Director of
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Reliability Engineering and Asset Management (REAM) MSc course, Head, Dynamics C
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Laboratory, and Head of Structures, Health and Maintenance (SHM) Group, School of
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Engineering, The University of Manchester, Manchester, M13 9PL, UK. S
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From the beginning (1989) of his professional career, Prof. Sinha was doing research in
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vibration and structural dynamics, including health monitoring techniques. Prof. Sinha was I
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also extensively involved in the development of a number of industrial innovative vibration- R
based techniques related to rotating machines, equipment and structural components. Prof. A
T
Sinha also received the prestigious award,“BOYSCAST (Better Opportunity for Young Scientist IO
in a Chosen Area of Science and Technology) Fellowship” in 1999 from the Department of N INDUSTRIAL APPROACHES
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ScienceandTechnology,GovernmentofIndiaforhisoutstandingworkinsolvinganumberof B
complex vibration-related problems to enhance plant reliability and reduce maintenance A
S
overhead of the nuclear power plants. Prof. Sinha moved to academiain 2005 after 16 years E IN VIBRATION-BASED
D
of industrial experience and then joined the University of Manchester, UK in January 2007.
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Since then, Prof. Sinha has widened his research activities.
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CONDITION MONITORING
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Prof. Sinha is an internationally well-known expert in Vibration-based Condition Monitoring
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and Maintenance of Machines and Structures. He is involved in and has solved a number of TI
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industrial vibration problems of machines and structures, by in-situ vibration measurements
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and analysis, in many plants the last 31 years. Prof. Sinha is the author of more than 250
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publications (books, journals, conferences, edited book/conference proceedings and technical O
reports) and has given a number of keynote/invited lectures around the world. N
Jyoti K. Sinha
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Mechanical Engineering
aninformabusiness
ISBN978-1-138-55033-9
,!7IB1D8-ffaddj!
www.crcpress.com
CRCPresstitlesareavailableaseBookeditionsinarangeofdigitalformats
Industrial Approaches
in Vibration-Based
Condition Monitoring
Industrial Approaches
in Vibration-Based
Condition Monitoring
Jyoti K. Sinha
CRC Press
Taylor & Francis Group
6000 Broken Sound Parkway NW, Suite 300
Boca Raton, FL 33487-2742
© 2020 by Taylor & Francis Group, LLC
CRC Press is an imprint of Taylor & Francis Group, an Informa business
No claim to original U.S. Government works
Printed on acid-free paper
International Standard Book Number-13: 978-1-138-55033-9 (Hardback)
This book contains information obtained from authentic and highly regarded sources. Reasonable efforts
have been made to publish reliable data and information, but the author and publisher cannot assume
responsibility for the validity of all materials or the consequences of their use. The authors and publishers
have attempted to trace the copyright holders of all material reproduced in this publication and apologize
to copyright holders if permission to publish in this form has not been obtained. If any copyright material
has not been acknowledged please write and let us know so we may rectify in any future reprint.
Except as permitted under U.S. Copyright Law, no part of this book may be reprinted, reproduced, trans-
mitted, or utilized in any form by any electronic, mechanical, or other means, now known or hereaf-
ter invented, including photocopying, microfilming, and recording, or in any information storage or
retrieval system, without written permission from the publishers.
For permission to photocopy or use material electronically from this work, please access www.copyright.
com (http://www.copyright.com/) or contact the Copyright Clearance Center, Inc. (CCC), 222 Rosewood
Drive, Danvers, MA 01923, 978-750-8400. CCC is a not-for-profit organization that provides licenses and
registration for a variety of users. For organizations that have been granted a photocopy license by the
CCC, a separate system of payment has been arranged.
Trademark Notice: Product or corporate names may be trademarks or registered trademarks, and are
used only for identification and explanation without intent to infringe.
Library of Congress Cataloging‑in‑Publication Data
Names: Sinha, Jyoti Kumar, author.
Title: Industrial approaches in vibration-based condition monitoring / Jyoti Sinha.
Description: Boca Raton : CRC Press, 2020. | Includes bibliographical
references and index.
Identifiers: LCCN 2019038663 | ISBN 9781138550339 (hardback) | ISBN
9781315147222 (ebook)
Subjects: LCSH: Vibration--Testing. | Vibration--Measurement. |
Machinery--Monitoring. | Nondestructive testing.
Classification: LCC TA355 .S524 2020 | DDC 620.3/7--dc23
LC record available at https://lccn.loc.gov/2019038663
Visit the Taylor & Francis Web site at
http://www.taylorandfrancis.com
and the CRC Press Web site at
http://www.crcpress.com
CRC Press
Taylor & Francis Group
6000 Broken Sound Parkway NW, Suite 300
Boca Raton, FL 33487-2742
© 2020 by Taylor & Francis Group, LLC Dedicated to my father
CRC Press is an imprint of Taylor & Francis Group, an Informa business
Mr. (Late) Jagdish Prasad Sinha
No claim to original U.S. Government works
(7 February 1936 to 27 January 2018)
Printed on acid-free paper
International Standard Book Number-13: 978-1-138-55033-9 (Hardback)
This book contains information obtained from authentic and highly regarded sources. Reasonable efforts
have been made to publish reliable data and information, but the author and publisher cannot assume
responsibility for the validity of all materials or the consequences of their use. The authors and publishers
have attempted to trace the copyright holders of all material reproduced in this publication and apologize
to copyright holders if permission to publish in this form has not been obtained. If any copyright material
has not been acknowledged please write and let us know so we may rectify in any future reprint.
Except as permitted under U.S. Copyright Law, no part of this book may be reprinted, reproduced, trans-
mitted, or utilized in any form by any electronic, mechanical, or other means, now known or hereaf-
ter invented, including photocopying, microfilming, and recording, or in any information storage or
retrieval system, without written permission from the publishers.
For permission to photocopy or use material electronically from this work, please access www.copyright.
com (http://www.copyright.com/) or contact the Copyright Clearance Center, Inc. (CCC), 222 Rosewood
Drive, Danvers, MA 01923, 978-750-8400. CCC is a not-for-profit organization that provides licenses and
registration for a variety of users. For organizations that have been granted a photocopy license by the
CCC, a separate system of payment has been arranged.
Trademark Notice: Product or corporate names may be trademarks or registered trademarks, and are
used only for identification and explanation without intent to infringe.
Library of Congress Cataloging‑in‑Publication Data
Names: Sinha, Jyoti Kumar, author.
Title: Industrial approaches in vibration-based condition monitoring / Jyoti Sinha.
Description: Boca Raton : CRC Press, 2020. | Includes bibliographical
references and index.
Identifiers: LCCN 2019038663 | ISBN 9781138550339 (hardback) | ISBN
9781315147222 (ebook)
Subjects: LCSH: Vibration--Testing. | Vibration--Measurement. |
Machinery--Monitoring. | Nondestructive testing.
Classification: LCC TA355 .S524 2020 | DDC 620.3/7--dc23
LC record available at https://lccn.loc.gov/2019038663
Visit the Taylor & Francis Web site at
http://www.taylorandfrancis.com
and the CRC Press Web site at
http://www.crcpress.com
Contents
Preface....................................................................................................................xiii
Author ......................................................................................................................xv
Chapter 1 Introduction ..........................................................................................1
1.1 Condition Monitoring ................................................................1
1.2 Condition Monitoring Techniques .............................................1
1.3 Condition-Based Maintenance ..................................................4
1.3.1 Lead-Time-to-Maintenance (LTM) .............................5
1.4 Summary ...................................................................................9
Chapter 2 Simple Vibration Theoretical Concept ...............................................11
2.1 Equation of Motion ..................................................................11
2.2 Damped System .......................................................................13
2.2.1 Equation of Motion for Free Vibration.......................14
2.2.2 Critically Damped System .........................................15
2.2.3 Over Damped System .................................................15
2.2.4 Under Damped System ...............................................16
2.3 Forced Vibration ......................................................................18
2.3.1 Example 2.1: An SDOF System .................................22
2.4 Concept of Modeshapes...........................................................23
2.5 Machine Vibration ...................................................................25
2.5.1 Rotor Dynamics .........................................................25
2.5.2 Unbalance Responses .................................................27
2.5.3 Machine Faults ...........................................................32
2.6 Summary .................................................................................33
References ..........................................................................................33
Chapter 3 Vibration-Based Condition Monitoring and Fault Diagnosis:
Step-by-Step Approach ......................................................................35
3.1 Introduction .............................................................................35
3.2 Different Stages of Vibration Measurements and
Monitoring ..........................................................................35
3.2.1 Bath Tub Concept .......................................................35
3.2.2 Stage 1—Machine Installation and Commissioning ......35
3.2.3 Stage 2—Machine Operation .....................................38
3.2.4 Stage 3—Aged Machines ...........................................42
3.3 Summary .................................................................................43
References ..........................................................................................43
vii
viii Contents
Chapter 4 Vibration Instruments and Measurement Steps .................................45
4.1 Introduction .............................................................................45
4.2 Sensors and Their Mounting Approach ..................................45
4.2.1 Displacement Sensor ..................................................45
4.2.2 Velocity Sensor ...........................................................47
4.2.3 Acceleration Sensor ....................................................48
4.2.4 Tacho Sensor ..............................................................53
4.3 Vibration Measurement ...........................................................55
4.3.1 A Typical Measurement Setup ...................................55
4.3.2 Steps Involved in the Data Collection ........................57
4.3.3 Instrument Calibration and Specifications .................59
4.3.4 Concept of Sampling Frequency ................................61
4.3.5 Aliasing Affect and Anti-aliasing Filter ....................61
4.3.5.1 Observations ...............................................65
4.3.6 Concept of Nyquist Frequency, f and the Useful
q
Upper Frequency Limit, f .........................................66
u
4.3.7 Analog-to-Digital Conversion (ADC) ........................67
4.4 Conversion of the Measured Data into the Mechanical Unit .....70
4.5 Summary .................................................................................71
References ..........................................................................................71
Chapter 5 Signal Processing ...............................................................................73
5.1 Time Signal .............................................................................73
5.1.1 Filters ..........................................................................73
5.1.2 Amplitude of Vibration ..............................................74
5.1.3 Integration of Time Domain Signal ...........................76
5.1.4 Statistical Parameters .................................................78
5.1.5 Comparison between CF and Kurtosis ......................79
5.2 Fourier Transformation (FT) ...................................................82
5.2.1 Example 5.1: A Sine Wave Signal ..............................83
5.2.2 Steps Involved for the Computation of FT .................84
5.2.3 Importance of Frequency Resolution in
Spectrum Analysis .....................................................87
5.2.4 Leakage ......................................................................88
5.2.5 Window Functions .....................................................89
5.3 Computation of Power Spectral Density (PSD) ......................92
5.3.1 Averaging Process ......................................................92
5.3.2 Concept of Overlap in the Averaging Process............94
5.3.3 Example 5.2: An Experimental Rig ...........................96
5.3.4 Example 5.3: An Industrial Blower ............................96
5.4 Conversion of Acceleration Spectrum to Displacement
Spectrum and Vice Versa ........................................................99
5.5 Short Time Fourier Transformation (STFT) .........................100
5.5.1 Example 5.4: An Experimental Rig .........................101
5.5.2 Example 5.5: An Industrial Centrifugal Pump ........101
Contents ix
5.6 Correlation between Two Signals ..........................................103
5.6.1 Cross Power Spectrum .............................................103
5.6.2 Transfer Function (Frequency Response
Function)...............................................................104
5.6.3 Ordinary Coherence .................................................104
5.6.4 Example 5.6: Two Simulated Signals with Noise .....105
5.6.5 Example 5.7: Laboratory Experiments .....................107
5.7 Concept of Envelope Analysis ...............................................109
5.8 Summary ...............................................................................111
References ........................................................................................111
Chapter 6 Vibration Data Presentation Formats ...............................................113
6.1 Introduction ...........................................................................113
6.2 Normal Operation Condition .................................................113
6.2.1 Overall Vibration Amplitude ...................................113
6.2.2 Vibration Spectrum ..................................................113
6.2.3 The Amplitude—Phase versus Time Plot ................115
6.2.4 The Polar Plot ...........................................................115
6.2.5 The Orbit Plot ...........................................................116
6.3 Transient Operation Conditions .............................................117
6.3.1 The 3D Waterfall Plot of Spectra .............................117
6.3.2 The Shaft Centerline Plot .........................................118
6.3.3 The Orbit Plot ...........................................................118
6.3.4 The Bode Plot ...........................................................119
6.4 Summary ...............................................................................120
References ........................................................................................120
Chapter 7 Vibration Monitoring, Trending Analysis and Fault Detection .......121
7.1 Introduction ...........................................................................121
7.2 Types of Faults .......................................................................125
7.3 Rotor Faults Detection ...........................................................125
7.3.1 Mass Unbalance .......................................................125
7.3.2 Shaft Bow or Bend ...................................................126
7.3.3 Misalignment ...........................................................127
7.3.4 Shaft Crack ...............................................................128
7.3.5 Shaft Rub ..................................................................128
7.4 Other Machine Fault Detection .............................................129
7.4.1 Mechanical Looseness .............................................129
7.4.2 Blade Passing Frequency (BPF) ...............................129
7.4.3 Blade Vibration and Blade Health Monitoring
(BHM) ...................................................................129
7.4.4 Electric Motor Defects .............................................129
7.5 Gearbox Fault Detection ........................................................130
