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EMAIL TIPS Volume 82 March 2012 A New Look

You may have noticed a new look to the Email Tips publication. We hope you like it! The hope is that Full Spectrum Diagnostics can add some real world insights into machinery maintenance and vibration analysis through a more visual format. The magazine format is provided by Issuu.com. It is our goal to promote sharing of ideas and solutions through our training side of the business and offer a view from the trenches via the field engineering and diagnostics side of the business.

The publication of the February Issue of Email Tips prompted several useful responses. Mostly, the comments focused on being able to access Issuu.com on company servers, problems with SPAM filters, downloading, and printing the color-filled format (not very ink friendly…).

To address these issues, the current publication and future issues will be distributed in multiple formats. The articles will be included in the body of the email for easy black & white printing. A PDF attachment to the email should enable an easy digital download. Finally, the Issuu.com link will be included for the heavily “on-line” readers.

I expect some additional distribution problems, but hopefully the most important aspect, the access to useful information will prevail. As always, your comments are welcome!

Dan Ambre [ModalGuy@aol.com] (763) 577-9959 www.fullspec.net

Features: The Time Waveform – The Beat Frequency Phenomena in the Time Waveform

The Spectrum – The Peak-Hold Averaging Methods in the detection of Resonance in the Operating Speed Range

Definitions: Operating Deflection Shape Analysis of Foundations and Fastened Joints – A Visual Interpretation

2012 Training Schedules

Core Training Courses: • Intro (IVA) – VAI – VAII – VAIII

Concentrated Training Courses: • TWF – Spectrum – Phase – Bearings

Specialty Training Courses: • ODS/Modal – Precision Balancing

Cover:

The cover features a large SKF 29434E cylindrical roller bearing photographed during replacement following a rapid onset of failure. The physically indirect measurement path to this bearing required a more detailed review of the vibration data and historic trends to eventually make the case to pull the unit (vertical pump application). The photo is interesting due to the angle and back lighting which reveals the rolling element’s bumpy ride on the raceway.

The failure was traced to improper loading (brinelling) during the installation operations. The vertical pump system was operated for nearly two years before the unit was pulled. The backup unit has been operating for eight years without issues.

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Definitions & Nomenclature: ODS Analysis of Foundations In mechanical systems and machinery applications the vibration levels from the driving sources in the machine are significantly attenuated across fastened connections and critical joints when attached properly, or as designed. Excessive vibration response occurs when resonant amplification or mechanical looseness exists or is transmitted across the fastened joints.

In rotating equipment, the vibration response is typically measured at the bearing housings (for rolling element type bearings) or at the rotor (as measured on fluid film type journal bearings). Elevated vibration levels can be related to numerous machinery malfunctions via vibration frequency analysis. Since the rotor itself is the source of the machine vibration, the amplitudes should be greatest at the bearing cap or rotor measurement locations. When the machine or structure is mapped with multiple measurements, as in Operating Deflection Shape (ODS) analysis, the transmission of that vibration energy can be evaluated. As the machine response is measured at locations further away from the rotor, the energy (vibration amplitude) should diminish.

When problematic mounting conditions exist, an excessive synchronous or harmonic vibration signature will result. The first indication of a fault is expected at the machine bearing or rotor locations, where the fault may be amplified. When the malfunction is related to the foundations or mounting location(s), the vibration levels will still show an attenuation effect (at the mounts) but will exceed the typical “foundation-level” response. The overall machine response will include a lifting of the unit, usually in the vertical direction. For taller structures with higher centers of gravity an elevated horizontal “rocking” response may result.

The ODS type analysis creates a visual assessment of the machinery which is exposed via computer animations. The measurement map should include numerous samples across the joints or connected (grouted) interfaces. The key response of a malfunction in a foundation typically shows a relative out-of-phase motion across the joint interfaces. As noted above, the energy in the machine will not diminish as would be expected, rather the overall machine motion may include a vertical lift or a horizontal rocking response in the structure. This “visual” evaluation is very effective when determining root cause failure in rotating machinery applications, or pin-pointing a source.

Motor “Rocking” on Faulty Mounting Frame

Grout Line Separation in Motor Mount

2012 CORE VIBRATION TRAINING SCHEDULE IMPLEMENTING A SUCCESSFUL PdM PROGRAM JUN 19-20 Cameron, WI 2012-PdM-01 Tuition: $ 945.00 / 2-day Format Proficiency Test: Included INTRODUCTION TO VIBRATION ANALYSIS FEB 21-22 St. Paul, MN 2012-INT-01 FEB 28-29 Harrisburg, PA 2012-INT-02 MAR 13-14 Brookfield, WI 2012-INT-03 APR 17-18 Knoxville, TN 2012-INT-04 Tuition: $ 945.00 / 2-day Format Proficiency Test: Included VIBRATION ANALYSIS I MAR 06-09 St. Paul, MN 2012-VA1-01 APR 10-13 Cedar Rapids, IA 2012-VA1-02 APR 24-27 Wheeling, WV 2012-VA1-03 SEP 11-14 Chicago, IL 2012-VA1-04 DEC 11-14 Charlotte, NC 2012-VA1-05 DEC 18-21 New Orleans, LA 2012-VA1-06 Tuition: $ 1,295.00 / 3-day Format Certification Exam: $ 200.00 VIBRATION ANLAYSIS II MAR 20-23 Leesport, PA 2012-VA2-02 MAY 08-11 Chicago, IL 2012-VA2-03 MAY 22-25 Cumming, GA 2012-VA2-04 JUL 10-13 St. Paul, MN 2012-VA2-05 SEP 25-28 Cedar Rapids, IA 2012-VA2-06 Tuition: $ 1,395.00 / 3-day Format Certification Exam: $ 200.00 VIBRATION ANALYSIS IIIa OCT 23-26 Leesport, PA 2012-VA3-01 Tuition: $ 1,595.00 / 4-day Format Certification Exam: $ 200.00 PRACTICAL VIBREATION ANALYSIS IIIb AUG 21-24 St. Paul, MN 2012-PVA-01 Tuition: $ 1,595.00 / 4-day Format Certification Exam: $ 200.00

2012 SPECIALTY VIBRATION TRAINING SCHEDULE MODAL & ODS ANALYSIS 2 MAR 20-22 Davenport, IA 2012-ODS-01 JUL 24-26 St. Paul, MN 2012-ODS-02 For In-Plant Training: ModalGuy@aol.com Tuition: $ 1,595.00 / 3-day Format One Month ME’scope Software Included CONC TIME WAVEFORM ANLAYSIS JUN 05-06 Cedar Rapids, IA 2012-TWF-01 NOV 27-28 Chillicothe, OH 2012-TWF-02 Tuition: $ 945.00 / 2-day Format Proficiency Test: Included CONCENTRATED SPECTRUM ANALYSIS

JUN 26-27 Brookfield, WI 2012-CSA-01 JUL 17-18 Davenport, IA 2012-CSA-02 OCT 02-03 St. Paul, MN 2012-CSA-03

Tuition: $ 945.00 / 2-day Format Proficiency Test: Included CONCENTRATED PHASE ANALYSIS SEP 18-19 Davenport, IA 2012-CPA-01 Tuition: $ 945.00 / 2-day Format Hands-on Exercises: Included CONCENTRATED RE BEARING & GEAR ANLAYSIS OCT 16-17 Cedar Rapids, IA 2012-BGA-01 Tuition: $ 945.00 / 2-day Format Proficiency Test: Included VIBRATION ANALYSIS FOR MOTOR SHOPS AUG 28-30 Charlotte, NC 2012-VAM-01 DEC 04-06 St. Paul, MN 2012-VAM-02 Tuition: $ 1,295.00 / 3-day Format Hands-on Exercises: Included PRECISION BALANCING !!! NEW !!! MAY 01-02 Cedar Rapids, IA 2012-BAL-02 AUG 07-08 Brookfield, WI 2012-BAL-03 NOV 13-14 Wheeling, WV 2012-BAL-04 Tuition: $ 945.00 / 2-day Format Hands-on Exercises: Included

THE VIBRATION FAULT GUIDE

The Vibration Fault Guide is a 110-page indispensable asset for every vibration analyst, as well as a helpful tool to bridge the gap between the analyst and his management staff.

Some 45 Rotating Machinery Faults are Identified and defined. Conveniently sized at 3” x 6”, it easily fits in your pocket for everyday use!

GUÍA DE FALLAS DE VIBRACIÓN

Este manual consta de 110 páginas y fue compilado por Full Spectrum Diagnostics como referencia rápida para la industria de Mantenimiento Predictivo y Monitoreo de Condición. La guía incluye ejemplos de espectros, formas de onda, definiciones de fallos y reglasde análisis de fase para aproximadamente unos 45 problemas que se pueden presentar en maquinaria rotativa.

También incluimos varios estándares de especificaciones de vibración, guías para definición de bandas de alarmas, fórmulas y definiciones de Procesamiento de Señales. Es suficientemente pequeño como para llevarlo en la bolsa de su camisa ( 3.5” X 6.0”), pero su contenido es tan grande que podría ser considerado como una guía de referencia esencial para la industria del Monitoreo de Condición.

THE VIBRATION TECHNIQUES GUIDE

The Vibration Analysis Techniques Guide is a 108-page pocket sized information treasure trove. Information on dozens of analysis techniques, specifications and data presentation formats are included.

If you liked the Vibration Fault Guide, your next educational step should be the Vibration Analysis Techniques Guide get yours now at: Order now at: http://www.fullspec.net/store.html Or by Phone @ (763) 577-9959

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THE VIBRATION ANALYSIS PERIODIC TABLE This Full Color Laminated 8 ½ x 11 inch card-stock table provides a “quick-look” method of distinguishing one machinery fault from another and suggests Diagnostic Tests or formula that may be used to build a case and make the call! Faults are classified by Frequency Content and grouped in similar patterns: Synchronous / Harmonic / Sub-Harmonic Sub-Synchronous / Non-Synchronous / Modulated (Sidebands)

Faults are Color classified Directionally: [ Radial ] / [ Axial ] / [ Radial & Axial ] Faults are Foot Noted to the Vibration Fault Guide for a more detailed reference. If you liked the Vibration Fault Guide, your next educational step should be the Vibration Analysis Periodic Table! Get yours now at: www.fullspec.net, or by phone at 763-577-9959