Class - 11

Condition Monitoring
Introduction – Vibration
to Reliability Analysis
Engineering

Ahmad Taufik, [Link]., Ph.D., CMRP

(Asset Integrity & Reliability Specialist)

Condition Monitoring
Vibration Analysis
 Maintenance
Maintenance
Classification

Preventive Corrective
Maintenance Maintenance

Time (Calendar) Conditioning Based CM Routine Work

Based Maintenance Maintenance (CBM) from PMs (Planned,
(TBM) – Age Related Predictive Scheduled)

Run Based Operator Based CM Major Repair

Maintenance (RBM) Maintenance (OBM) PMs (Planned,
Usage Related Operator/TPM Scheduled)

CM Reactive
(Unplanned/Breakdown/
Condition Monitoring Emergency)
Vibration Analysis
Condition Based Maintenance (CBM)
CBM / PdM technologies used to evaluate assets condition include:
❑ Vibration analysis
❑ Shock Pulse Method (SPM)
❑ Oil analysis
❑ Infrared (IR) thermography
❑ Partial discharge & Corona detection
❑ Acoustic / Ultrasonic — sound level measurements
❑ Electrical — amperage plus other data
❑ Operational performance data — pressure, temperature, flow
rates, etc.

Condition Monitoring
Vibration Analysis
CBM Technology consist any condition-based maintenance program can be
characterized by a combination of three phases:
❑ Surveillance — monitoring machinery condition to detect incipient
problems
❑ Diagnosis / Prognosis — isolating the cause of the problem and
developing a corrective action plan
❑ Remedy — performing corrective action
Condition monitoring uses primarily nonintrusive testing techniques, visual
inspections, and performance data to assess machinery condition
Continuing analysis of the asset condition allows planning and scheduling of
maintenance or repairs in advance of catastrophic or functional failure.

Condition Monitoring
Vibration Analysis
The P-F curve, or Prevention – Failure curve, is a graph used to identify
asset reliability and performance over time. It plots the interval between an
asset's potential failure (P) and functional failure (F), which allows you to
identify when preventive maintenance measures should be taken.

Condition Monitoring
Vibration Analysis
 Part 1
Fundamental of Vibration Analysis

Condition Monitoring
Vibration Analysis
 The Purposes of the Vibration Test and Analysis

1. See the actual condition of rotating equipment (gas engine, diesel

engine, pump, compressor and blower).
2. To study whether the vibration level of the rotary equipment is still
within safe limits based on ISO 10816, or if corrective action is
needed.
3. As part of the RCM study to obtain primary data which is part of
condition monitoring in addition to lubrication analysis and infrared
thermal inspection.
4. Plan the 2026 inspection and test plan based on the results of the
RCM study by considering the priority scale (criticality level) and
failure modes that occur.

Condition Monitoring
Vibration Analysis
Condition Monitoring
Vibration Analysis
 Condition Monitoring
(Vibration Monitoring & Analysis)

❑ Vibration analysis is diagnostic

tool to determine the machine
health status by analyzing its
spectrum vibration data.
❑ Waveform amplitude indicate the
severity and the spectrum
indicates the failure modes. FFT

Condition Monitoring
Vibration Analysis
Condition Monitoring
Vibration Analysis
 Vibration Analysis
❑ Vibration usually indicates trouble in the machine. Machine and
structures vibrate in response to one or more pulsating forces that may
be due to unbalance, misalignment, etc.
❑ The magnitude of vibration is dependent on the force and properties of
the system, both of which may depend on speed.
❑ The frequency spectrum indicates the machine failure modes and the
amplitude indicates the intensity of failure rate/damage.

Condition Monitoring
Vibration Analysis
Trend Analysis of Vibration and Maintenance Activities

Condition Monitoring
Vibration Analysis
Condition Monitoring
Vibration Analysis
Condition Monitoring
Vibration Analysis
 Vibration Analysis
❑ There are four fundamental characteristics of vibration: frequency,
period, amplitude, and phase.
❑ The period is the time required to complete one cycle of vibration.
Therefore, it is reciprocal of frequency (CPM or Hz)
❑ The operating speed of an asset or machine is usually expressed in
revolution per minute (RPM).
❑ The amplitude is the maximum value of vibration at a given location of
the machine.
❑ Phase is the time relationship between vibrations of the same frequency
and is measured in degrees.

Condition Monitoring
Vibration Analysis
Vibration Analysis
 Vibration Analysis

The three key measures used to evaluate the magnitude of

vibrations are:
❑ Displacement
❑ Velocity
❑ Acceleration.
Vibration Analysis
Vibration Analysis
Vibration Analysis

Condition Monitoring
Vibration Analysis
 Vibration Analysis
❑ Displacement measurement is the dominant at low frequency and is
caused by stresses in flexible members of the machine
❑ Displacement is a good measure for low frequency vibration, usually ,
< 20 Hz. Velocity is the time-rate change of displacement. It is
dependent upon both displacement and frequency.
❑ The greater the displacement and the frequency of vibration, the
greater is the severity of machine vibration at the measured location.
❑ Velocity is used to evaluate machine condition in the frequency range
of 10 - 1,000 Hz.
❑ The acceleration is the dominant measure at higher frequencies that
exceed 1,000 Hz.
❑ Acceleration is proportional to the force on machine components such
as gears and couplings.

Condition Monitoring
Vibration Analysis
 Vibration Analysis
❑ For a given acceleration magnitude A, velocity and displacement
magnitudes can be defined as:
Velocity V = A/(2 π f)
Displacement D = V/(2πf) = A/[(2 π f)2]
where f is the frequency of vibration.
❑ Similarly for a given velocity magnitude V, the acceleration and
displacement magnitudes can be defined as:
Acceleration A = V (2 π f)
Displacement D = V / (2 π f)
❑ For a given displacement D, the acceleration and velocity
magnitudes can be defined as:
Velocity V = D (2 π f)
Acceleration A = V (2 π f) = D (2 π f)2
Condition Monitoring
Vibration Analysis
 Vibration Analysis
With a few exceptions, mechanical troubles in a machine cause vibration.
The most common problems that produce vibration are:
❑ Unbalance of rotating parts
❑ Misalignment of couplings and bearings
❑ Bent shafts
❑ Worn, eccentric, or damaged parts
❑ Bad drive belts and chains
❑ Damaged / bad bearings
❑ Looseness
For example, when analyzing a 3600 RPM
❑ Rubbing pump motor, a peak at 3600 RPM
❑ Aerodynamic and other forces indicates some kind of mass imbalance. A
peak at 7200 RPM (two times the
rotational frequency) generally indicates a
bent shaft.

Condition Monitoring
Vibration Analysis
Condition Monitoring
Vibration Analysis
Condition Monitoring
Vibration Analysis
 Vibration Analysis
❑ Under conditions of dynamic stress, displacement alone may be a
better indication of severity, especially when the asset components
exhibit the property of brittleness — the tendency to break or snap
when stressed beyond a given limit.
❑ Consider a slowly rotating machine that operates at 60 RPM, and that
exhibits vibration of 20 mils peak-to-peak displacement caused by
rotor unbalance. Note: 1 mils = 0.001 inch = 0.0254 mm.
❑ In terms of vibration velocity, 20 mils at 60 CPM (1 Hz) is only 0.0628
in/sec [V = 2(3.14)(1)(0.02/2) = 0.0628].
❑ This level would be considered good for general machinery and little
cause for immediate concern. However, keep in mind that the bearing
of this machine is being deflected 20 mils.
❑ Under these conditions, fatigue may occur due to stress (resulting
from the displacement) rather than due to fatigue (caused by the
velocity of displacement). Condition Monitoring
Vibration Analysis
 Quick Test
1. What is frequency in Hz of the engine if the speed is 1000
rpm, 5000 rpm and 10000 rpm?
2. What (mm) is the amplitude of 20 mils?
3. If the displacement amplitude (D) is 100 mils at 6000 rpm,
calculate the velocity amplitude (V) and acceleration
amplitude (A) of the jet engine.
4. If the natural structural of the jet engine in problem no 3
above is 105 Hz, what would happen?

Condition Monitoring
Vibration Analysis
Machinery Diagnostic Vibration Analysis

Condition Monitoring
Vibration Analysis
Vibration Analysis of Imbalanced

Condition Monitoring
Vibration Analysis
Vibration Analysis of Imbalanced

Condition Monitoring
Vibration Analysis
Vibration Analysis of Misalignment

Condition Monitoring
Vibration Analysis
Vibration Analysis of Misalignment

Condition Monitoring
Vibration Analysis
Vibration Analysis of Looseness

Condition Monitoring
Vibration Analysis
Vibration Analysis of Looseness

Condition Monitoring
Vibration Analysis
Condition Monitoring
Vibration Analysis
Vibration Analysis of Looseness
Vibration Analysis of Looseness

Condition Monitoring
Vibration Analysis
Vibration Analysis of Bearing Wear

Condition Monitoring
Vibration Analysis
Condition Monitoring
Vibration Analysis
Vibration Analysis of Bearing Wear

Condition Monitoring
Vibration Analysis
Vibration Analysis of Bearing Wear

Condition Monitoring
Vibration Analysis
 Vibration Analysis Results
Introduction(Case Study) Engineering
to Reliability

Inspection & Engineering Team

Condition Monitoring
Vibration Analysis
 Part 2
Case Study on Gas Turbine

Condition Monitoring
Vibration Analysis
Condition Monitoring
Vibration Analysis
Condition Monitoring
Vibration Analysis
A Typical Solar Turbine

Condition Monitoring
Vibration Analysis
Condition Monitoring
Vibration Analysis
Condition Monitoring
Vibration Analysis
 The Purposes of the Vibration Test and Analysis

1. See the actual condition of rotating equipment (gas engine, diesel

engine, pump, compressor and blower).
2. To study whether the vibration level of the rotary equipment is still
within safe limits based on ISO 10816, or if corrective action is
needed.
3. As part of the RCM study to obtain primary data which is part of
condition monitoring in addition to lubrication analysis and infrared
thermal inspection.
4. Plan the 2026 inspection and test plan based on the results of the
RCM study by considering the priority scale (criticality level) and
failure modes that occur.

Condition Monitoring
Vibration Analysis
ISO 10816 (Part – I)

Condition Monitoring
Vibration Analysis
ISO 10816 (Part – 6)

Condition Monitoring
Vibration Analysis
 ISO 10816 (Part – 6)
Diesel Engine Acceptance Criterion

Condition Monitoring
Vibration Analysis
Machinery Diagnostic Vibration Analysis
CAT G3406 - Gas Generator Sets

Engine Specification

Capacity 160 KW /200 KVA

Running Hours 35326 Hours

Speed – Design Specification 1500 rpm

Running Speed – Actual During

1500 rpm
Vibration Test
Vibration Analysis Results
Gas Engines Generator

Condition Monitoring
Vibration Analysis
Vibration Test Locations

EG = Electrical Generator
CE = Combustion Engine
DE = Drive End
NDE = Non-Drive End
B = Bottom/Support
L = Left
R = Right

Condition Monitoring
Vibration Analysis
 Low Vibration Level at Drive
End
(Combustion Engine)

Position Vibration Waveform Graph Vibration Spectrum Graph Max Value

Rainflow Spectrum
Drive End (DE) (mm/sec)
Direction

V 3,41

H 3,31

A 3,86
 High Vibration Level at Bottom/Base Right Drive End
(Combustion Engine)

Direction Bottom Left Drive End (BL-DE) - Bottom (Support)

V 10,867

Direction Bottom Right Dive End (BR-DE)

V 10,33

Condition Monitoring
Vibration Analysis
 Vibration at Bottom Left Drive End (BL-DE) – Vertical

Possible Failure Modes

Combustion Engine
in Combustion Engine
(CE)
1. Looseness
2. (Mass Imbalance)

No High Vibration Level

Observed on Electrical
Generator (EG)

Vibration at Bottom Right Drive End (BR-DE) – Vertical

Conclusions
Combustion Engine In general, based on ISO
10816-6, the engine gas
vibration level is still
included in the acceptance
criteria (Vmax = 20 to 35
mm/sec), for the type of
vibration severity grade 18
to 45.
Vibration Analysis Results
Diesel Engine Generator

Condition Monitoring
Vibration Analysis
 CAT G3406 – Diesel Engine Generator

Engine Specification

Capacity 256 KW /320 KVA

Running Hours 1098 Hours
Running Speed – Design Specification 1500 rpm

Running Speed – Actual During Vibration Test 1500 rpm

Vibration Test Locations

Condition Monitoring
Vibration Analysis
 Medium Vibration Level at
Bottom Left Drive End
(Electrical Generator)

Direction Bottom Left Drive End (BL-DE) - Bottom (Support)

V 6,19

H 3,95

A 1,17
 Vibration at Bottom Left Drive End – Horizontal

Electrical Generator

Possible Failure Modes

in Electric Generator
Vibration at Bottom Left Drive End – Vertical (EG)
1. Looseness
Electrical Generator 2. Mass Imbalance
3. (Bearing)

However, they are still

in safe zone
Vibration at Bottom Left Drive End – Axial

Electrical Generator
 Vibration Level at Drive End
(Combustion Engine)

Position Vibration Waveform Graph Vibration Spectrum Graph Max Value

Drive End (DE) (mm/sec)
Direction

V 5,62

H 4,67

A 5,24
 Vibration at Bottom Left Drive End – Axial

Combustion Engine

Possible Failure Modes

in Combustion Engine
(CE)
1. Looseness
2. Mass Imbalance
Vibration at Bottom Right Drive End – Vertical
No High Vibration Level
Observed on Electrical
Combustion Engine Generator (EG)

Summary & Conclusions

1. Diesel engines show a tendency for looseness and mass imbalance for the combustion
engine part plus the possibility of initial bearing damage to the electrical generator.
2. However, in general based on ISO 10816-6, the vibration level of the diesel engine is still
included in the acceptance criteria (Vmax = 20 to 35 mm/sec), for the type of vibration
severity grade 18 to 45.
Vibration Analysis Results
Fire Water Main Pump

Condition Monitoring
Vibration Analysis
 Vibration Test Locations

Engine Specification

Capacity 62 KW EG = Electrical Generator

CE = Combustion Engine
Running Hours NA
DE = Drive End
Running Speed – Design NDE = Non-Drive End
2970 rpm (TBC)
Specification B = Bottom/Support
Running Speed – Actual L = Left
8940 rpm
During Vibration Test R = Right
 Vibration Level at Drive End
(Main Pump)

Position Vibration Waveform Graph Vibration Spectrum Graph Max Value

Direction Drive End (DE) (mm/sec)

V 4,9

H 2,65

A 4,22
Direction Bottom Left Non Drive End (BL-NDE) - Bottom (Support)

V 1,72

Direction Bottom Right Dive End (BR-DE)

V 6,94

Direction Bottom Right Dive End (BR-DE)

V 6,94

Direction bottom Right Non Drive End (BR-NDE)

V 8,01
 Vibration at Bottom Right Drive End – Vertical

Main Pump Possible Failure Modes

in Main Pump (PU)
Mass Imbalance

No High Vibration Level

Observed on Electrical
Motor (EM) Section

Vibration at Bottom Right Non-Drive End – Vertical

Main Pump Summary and Conclusions

Fire Water Main Pump shows
mass imbalance. However, it is
still within safe limits based on
ISO 10816-6.
Vibration Analysis Results
Fire Diesel Pump

Condition Monitoring
Vibration Analysis
 Vibration Test Locations

Engine Specification

Capacity 62 KW
Running Hours 27.4
Speed – Design Specification 3000 rpm

Speed – During Vibration Test 3060 rpm

Position Vibration Waveform Graph Vibration Spectrum Graph Overall
(mm/sec)
Direction Drive End (DE)

V 26,1

H 21,41
Direction Non Drive End (NDE)

V 17,18

H 13,04

A 6,43
Vibration Waveform Graph Vibration Spectrum Graph Max Value
Rainflow Spectrum
Drive End (DE) (mm/sec)

3,3

11,4
Condition Monitoring
Vibration Analysis
Vibration at Drive End – Vertical

Fire Diesel Pump – Combustion Engine

Engine Firing Frequency

2.5 x running speed
(5-Cylinder 4-stroke engines)

Vibration at Drive End – Horizontal

Fire Diesel Pump – Combustion Engine

Possible Failure Modes in

Combustion Engine is
Engine Frequency
Running Speed = 51 Hz Shaft Misalignment
Vibration at Non-Drive End – Vertical

Fire Diesel Pump – Combustion Engine

Possible Failure Modes in

Combustion Engine is
Vibration at Non-Drive End – Horizontal Shaft Misalignment

Fire Diesel Pump – Combustion Engine

Vibration at Drive End – Axial

Fire Diesel Pump – Pump Possible Failure Modes in

Pump is
Early bearings problem
 Summary & Conclusions
1. There is a slight difference in the running speed of the diesel engine
which should be 3000 rpm (50 Hz) to 3060 Hz (51 Hz), which is
indicated by the 2x frequency spectrum (102 Hz).
2. In this diesel engine, there is a vibration phenomenon related to
firing frequency (5 cylinders, 4 strokes), namely 51 Hz x 2.5 = 127
Hz).
3. In addition, there are vibrations with various frequency spectrums
related to engine performance (e.g. torque pulsating, piston &
connecting rod movement, crankshaft, etc.).
4. Diesel engines show possible shaft mis-alignment and early bearing
problems.
5. However, for vibration severity grade 45 based on ISO 10816-6, the
vibration level of the diesel engine is still included in the acceptance
criteria (Vmax = 35 mm/sec).
Vibration Analysis Results
Oil Centrifugal Pump

Condition Monitoring
Vibration Analysis
 Desain and Operation Parameters
Motor Data Pump Data

Tag. No : 055-A-101P2B Tag. No : 055-A-101P2B

Type : Electric Motor Type : Centrifugal Pump
Voltage : 400 V / 50 Hz / 3 Voltage : 400 V / 50 Hz / 3
Phase Phase
Power : 30 KW Power : 30 KW
Speed : 2940 RPM Speed : 2940 RPM
Bearing : 6312ZZC3 Bearing : 6309 C3
6311ZZC3 3309 C3
Coupling : flexible disc type Coupling : flexible disc type
spacer (rubber) spacer (rubber)

Measurement Parameters
o Vibration data in overall time intervals.
o Waterfall chart.
o The frequency domain (vibration spectrum) of each date.
o The maintenance process is carried out on the machine.
 DATA ANALYSIS AND DISCUSSION

❑ On 18/09/2014 there was a

clutch damage with problems in
the fulfillment of minimal spare
parts, so the replacement of the
rubber type flexible clutch was
carried out through modification
using teflon material produced
by itself in the rotating
equipment workshop.
❑ On 19/03/2015 with the
shutdown process, the flexible
clutch was replaced with Teflon
Condition Monitoring
Vibration Analysis
 DATA ANALYSIS AND DISCUSSION
v [mm/s] 055-A-101 P2B\Mo to r\IB Axia l\1128 Ov e ra ll v e lo c ity .v ib
9

On the waterfall graph, you can see that

(11/08/2015 [Link] / 7,90)
8 D

6 there are many amplitudes of the spectrum

5

4 that are visible, but with amplitudes dominant

3

2
(28/10/2015 [Link] / 1,44)
M at 1x, 2x, and 3x rpm.
1

0
15/10/2014 10/12/2014 04/02/2015 01/04/2015 27/05/2015 22/07/2015 16/09/2015 11/11/2015
date
v rms [mm/s] 055-A-101 P2B\Mo to r\IB Axia l\1129 Ma c h.s p e c tr.v e l 12/10/2015 [Link]

The initial analysis was RPM : 3000 (50,00Hz)

M(x) : 3000,00 cpm (1,00 Orders)
M(y) : 2,29 mm/s

carried out in the axial

direction by taking three 7,0

6,0
measurement times, namely 5,0
01/12/2014
19/03/2015
4,0 (3000,00 / 2,29) 16/04/2015

on 01/12/2014, 19/03/2015, 3,0

M 27/04/2015
28/07/2015
2,0 11/08/2015
and 11/08/2015. 1,0
30/09/2015
12/10/2015
0,0 28/10/2015
0 5000 10000 15000 20000 25000 30000 35000
f [cpm]

Condition Monitoring
Vibration Analysis
In comparison, the magnitude of the amplitude in the vertical direction
is 2.65 mm/s
v rms [mm/s] 055-A-101 P2B\Mo to r\IB Axia l\1129 Ma c h.s p e c tr.v e l 01/12/2014 [Link]
7,0
RPM : 3000 (50,00Hz)
6,5 M(x) : 3005,00 cpm (1,00 Orders)
M(y) : 0,14 mm/s
6,0 D(x) : 6010,00 cpm (2,00 Orders)
5,5 D(y) : 0,80 mm/s

5,0
4,5
4,0
3,5
3,0
2,5
2,0
1,5
(6067,50 / 0,60)
1,0 D
0,5 3
M 4 5
0,0
0 2000 4000 6000 8000 10000 12000 14000 16000 18000 20000 22000 24000
f [cpm]

For axial direction, misalignment requires amplitude of fifty percent or more

of the radial direction, so 50% of 2.65 is 1.325. Compared to the amplitude
of 0.80 mm/s in the axial direction, it is still far from 1.325 mm/s.
The amplitude at 2x rpm of 5.02 mm/s shows a far comparison, with
1x rpm being five times greater. The amplitude at 2x rpm of 5.02 mm/s
shows a far comparison, with 1x rpm being five times greater. To
further ascertain the misalignment that occurs.
v rms [mm/s] 055-A-101 P2B\Mo to r\IB Axia l\1129 Ma c h.s p e c tr.v e l 19/03/2015 [Link]
7,0
RPM : 3000 (50,00Hz)
6,5 M(x) : 3002,50 cpm (1,00 Orders)
M(y) : 0,84 mm/s
6,0 D(x) : 6005,00 cpm (2,00 Orders)
5,5 D(y) : 5,02 mm/s
D
5,0
4,5
4,0
3,5
3,0
2,5
2,0
1,5
(6060,00 / 0,73) 3
1,0 M
4 5
0,5
0,0
0 2000 4000 6000 8000 10000 12000 14000 16000 18000 20000 22000 24000
f [cpm]

❑ The radial measurement direction shows a horizontal amplitude of

5.09 mm/s and a vertical 1.96 mm/s.
❑ With a 50% calculation of 5.09 being 2.545, then the amplitude of 2x
rpm of 5.02 is twice as great as 2.545 mm/s.
❑ Indications of Angular Misalignment
 v rms [mm/s] 055-A -101 P 2B \ Mo to r\ IB A xia l\ 1129 Ma c h.s p e c tr.v e l 11/ 08/ 2015 [Link]
7,0
RPM : 3000 (50,00Hz)
6,5 D M(x) : 3002,50 cpm (1,00 Orders)
M(y) : 1,49 mm/s
6,0 D(x) : 6005,00 cpm (2,00 Orders)
5,5 D(y) : 6,32 mm/s

5,0
4,5
4,0
3,5
3,0
2,5
2,0
M 3
1,5 (6060,00 / 0,91)
4
1,0
0,5
5
0,0
0 2000 4000 6000 8000 10000 12000 14000 16000 18000 20000 22000 24000
f [cpm]

❑ The amplitude ratio of 2x rpm is four times greater than 1x rpm.

❑ Compared to the radial direction on 11/08/2015 at horizontal 3.24 mm/s
and vertical 2.56 mm/s, the axial direction is even twice as great.
❑ With this comparison, it shows that the pump shaft has been damaged in
the form of angular misalignment.
Condition Monitoring
Vibration Analysis
 CONCLUSIONS

• There was a significant increase by crossing each alert high and

danger high limit on 19/03/2015 and 11/08/2015.
• The amplitude comparison on the date of the machine with
normal conditions 01/12/2014 with the two dates of high
amplitude and the condition of the machine according to the ISO
standard color is:

Horizontal Vertical Axial

Date
(mm/s) (mm/s) (mm/s)

01/12/2014 3,95 2,65 0,80

19/03/2015 5,09 2,27 5,02

11/08/2015 3,24 2,56 6,32

Condition Monitoring
Vibration Analysis
 CONCLUSIONS
❑ There are some resonances appearing above 1x rpm which
makes the amplitude even larger.
❑ The comparison of radial amplitude with axial at the time of
damage of more than fifty percent strengthens the occurrence of
misalignment cases in the shaft.
❑ From field observation and analysis, the frequent shutdown of
the pump was due to high vibration related to angular
misalignment on the shaft. This failure modes was caused by
clutch damage as evidenced by Teflon flakes on the clutch.
Thank You Much