Practical Machinery Vibration Analysis and Predictive Maintenance

Practical Machinery Vibration Analysis and Predictive Maintenance
Paresh Girdhar BEng (Mech. Eng), Girdhar and Associates
Edited by
C. Scheffer PhD, MEng, SAIMechE
Series editor: Steve Mackay
Contents
Preface .vii
1 Predictive maintenance techniques: Part 1 Predictive maintenance basics .1
1.1 Maintenance philosophies 1
1.2 Evolution of maintenance philosophies .4
1.3 Plant machinery classification and recommendations .5
1.4 Principles of predictive maintenance 6
1.5 Predictive maintenance techniques 7
1.6 Vibration analysis – a key predictive maintenance technique 8
2 Predictive maintenance techniques: Part 2 Vibration basics 11
2.1 Spring-mass system: mass, stiffness, damping .11
2.2 System response .12
2.3 What is vibration? 13
2.4 The nature of vibration .14
2.5 Harmonics .18
2.6 Limits and standards of vibration .23
3 Data acquisition 29
3.1 Introduction 29
3.2 Collection of vibration signal – vibration transducers,
characteristics and mountings 29
3.3 Conversion of vibrations to electrical signal .39
3.4 Conclusion .54
4 Signal processing, applications and representations 55
4.1 The fast Fourier transform (FFT) analysis .55
4.2 Time waveform analysis 64
4.3 Phase signal analysis 67
4.4 Special signal processes .69
4.5 Conclusion .88
5 Machinery fault diagnosis using vibration analysis .89
5.1 Introduction 89
5.2 Commonly witnessed machinery faults diagnosed
by vibration analysis 89vi Contents
6 Correcting faults that cause vibration . 134
6.1 Introduction . 134
6.2 Balancing 134
6.3 Alignment . 145
6.4 Resonance vibration control with dynamic absorbers . 164
7 Oil and particle analysis 168
7.1 Introduction . 168
7.2 Oil fundamentals . 169
7.3 Condition-based maintenance and oil analysis . 172
7.4 Setting up an oil analysis program 175
7.5 Oil analysis – sampling methods . 179
7.6 Oil analysis – lubricant properties . 189
7.7 Oil analysis – contaminants in lubricants 196
7.8 Particle analysis techniques 201
7.9 Alarm limits for various machines (source: National Tribology
Services) . 219
7.10 Conclusion 220
8 Other predictive maintenance techniques . 221
8.1 Introduction 221
8.2 Ultrasound 221
8.3 Infrared thermography 229
8.4 Conclusion 234
Appendix A: Exercises 235
Appendix B: Practical sessions . 248
Index
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