Practical Case Studies On Vibration Analysis Pdf ❲99% PREMIUM❳

Before delving into specific case studies, it is essential to understand why vibration analysis occupies such a central role in modern industrial maintenance. Vibration analysis is not merely a diagnostic tool; it is the most widely adopted method for predictive maintenance across the industrial sector. In condition monitoring programs, vibration analysis typically accounts for approximately 50% of all activities, making it the single most important technique for assessing equipment health.

: A systematic review covering data acquisition, signal processing, and AI-based fault recognition.

2× RPM dropped to 1.2 mm/s. Fan ran smoothly for 10+ months.

Rolling element bearings are vital components in rotating machinery, and the majority of machinery malfunctions originate from rotating parts. Detecting bearing faults early is essential for preventing catastrophic failure, but manual observation of vibration signals is often insufficient because fault-related features are subtle and easily obscured by background noise. Practical Case Studies On Vibration Analysis Pdf

: Routine monthly readings at a bio-ethanol plant revealed increasing "Peak-to-Peak G" levels reaching 69 Gs. Spectral analysis showed harmonics matching Outer Race Damage (BPFO) frequencies. The root cause was identified as electrical erosion from stray eddy currents, solved by fitting an insulated bearing.

| Industry / Component | Title / Source | Key Fault Addressed | Key Takeaways | | :--- | :--- | :--- | :--- | | | Vibration Monitoring of Induction Motors: Practical Diagnosis of Faults via Industrial Case Studies by William T. Thomson (Cambridge University Press, 2020) | Shaft misalignment, soft foot, rolling and sleeve bearing faults, resonance, inverter noise | Contains 30 real-world industrial case studies , from initial spectrum analysis to final strip-down, and practical guidelines for grease management | | General Industry | Case Histories in Vibration Analysis and Metal Fatigue for the Practicing Engineer by Anthony Sofronas (John Wiley & Sons, 2012) | Various problems in fixed and rotating equipment, pressure vessels, and metal fatigue | Takes a simple, analytical approach emphasizing practical applicability over theory, based on author's personal industry experience | | General Machinery | Practical Case Studies on Vibration Analysis by Debasis Bhattacharyya (Notion Press, 2021) | Wide range of real-life problems encountered in machinery | 30 authentic case studies covering basics of vibration analysis, useful for beginners and practicing engineers | | Electric Motors | Aplicação de análise de vibração como técnica de preditiva em motores de um parque industrial (Federal University of Ceará, 2022) | Failures in centrifugal pumps and industrial exhaust fans | Demonstrates how FFT-based vibration analysis is used for predictive maintenance on critical equipment in an industrial park | | Centrifugal Compressor | Troubleshooting Centrifugal Compressor Trips Caused by High Vibration on Drive End Journal Bearing (SPE, 2020) | High vibration causing repeated machine trips | Systematically tracks the root cause to residual rotor unbalance and solves it by adjusting bearing clearances and lube oil pressure | | Turbo-compressor Unit | Unexpected Vibrations in Gearbox Caused by System Integration Issues (TAMU, 2018) | High radial vibration in a gearbox low-speed shaft | Unique case highlighting a torsional-lateral cross coupling issue; root cause was the lube oil pump working in aeration condition, not the gearbox itself | | Gearbox (Two-stage) | Condition Monitoring of Two-Stage Spur Gearbox Using Vibration Signature Spectrum Analysis (Springer, 2022) | Misalignment progressing to gear failure | Utilizes ISO 10816 guidelines over 5,400 hours of testing , tracking the progression from initial misalignment to final catastrophic failure with broken teeth | | Planetary Gearbox | Vibration monitoring for planetary gearbox in vertical axis coal mill (Mobius Connect Conference, 2018) | Gear faults in complex planetary systems | Addresses the unique challenges of analyzing planetary gearboxes where multiple gears mesh simultaneously (sun, planet, and ring gear) | | Industrial Fan (Case 1) | Chronic High Vibration in a Draft Fan (ASME Press, 2002) | Unbalance in a fan on a flexible support structure | Classic example of how structure dynamics complicate a simple balancing job on a 6th-floor installation | | Industrial Fan (Case 2) | An Economic Solution to a Vibration Problem: Large Critical Fan Case Study (Reliabilityweb.com) | Vibration caused by poor machine mounting | Demonstrates how an organized plan fixes the root source; shows before/after results of improved anchoring | | Soft Foot Defect | Using Vibration Response to a Soft Foot Defect with DCS Process Data (Reliabilityweb.com, 2025) | Soft foot causing a "weird vibration trending pattern" | Innovatively uses amplified video to visualize a 0.748 mils movement, cross-referencing vibration data with process variables | | Resonance | Resonance in Piping Support Structures (CTC, 2024) | Excessive vibration in a chiller's piping support structure, not the chiller itself | Uses impact testing to confirm resonance; highlights that supporting structures can be the source of vibration | | Pump Systems | Analysis of shaft alignment on vibration and motor power consumption in cooling water pumps (Univ. of Surabaya, 2026) | Angular misalignment in a cooling water pump | Confirms angular misalignment as the dominant factor for instability, linking it to higher energy consumption | | Locomotive Engine | Vibration Analysis of a Locomotive Diesel Engine (Mobius Connect Live, 2022) | High vibration after an engine overhaul | Step-by-step process using phase analysis and ODS, revealing two incorrectly installed balance gears |

A gearbox in a power generation plant was experiencing high vibration levels, leading to concerns about its reliability. A vibration analysis was conducted using a vibration analyzer. The results showed a high level of vibration at 2 times the gear mesh frequency (2x GMF). This indicated a potential problem with misalignment of the gearbox. Upon inspection, it was found that the gearbox was indeed misaligned, causing the gears to mesh improperly. The gearbox was realigned, and the vibration levels returned to normal. Before delving into specific case studies, it is

: A pump operating at 5100 RPM showed elevated vertical vibration at 1x RPM.

are you trying to monitor (e.g., pumps, fans, compressors)?

The case studies reviewed generally employ the following analysis techniques: : A systematic review covering data acquisition, signal

Vibration analysis acts as a critical predictive maintenance tool, with case studies highlighting its effectiveness in detecting faults like bearing damage in paper production and resonance in rocket engine nozzles. Documented examples show that identifying specific vibration frequencies can prevent failures in industrial machinery and marine equipment. For a comprehensive collection of 30 authentic case studies, explore the resource on Google Books I-care Group Case Study | Route-based Vibration Analysis - I-care

Vibration Basics and Machine Reliability Simplified: A Practical Guide to Vibration Analysis . (2020). Zenodo.