PresentedBy: MichaelMiller REMason
OperationalChallengesofToday
Ourtargetiszerounplanneddowntime
MaximizeEquipmentAvailability&Reliability
PlanALLMaintenance HOW?
Wearetryingtobecompetitivetodaywithaplant thatistypicallymorethan40yearsold andso areourcompetitors.
ExtendMachineryLife&Rebuilds
Wearerunningourequipmentbeyond itsdesign capacity tohandlethevarietyofmaterialsthatwe mustprocess
IncreasedthroughputwithoutRISKofmachinefailure?
Vibration Basics (Miller) 2
AnswerTheseToughQuestions...
Whatmaintenancedoesthemachineneedduringthe nextplannedshutdown?
DoIhavetheparts,doIhavethepeople?
Cantheequipmentrunbeyondthenextscheduled outage?
WhatworkcanIsafelyscheduleoutuntilthenext shutdown?
Vibration Basics (Miller)
WhatisVibration?
Vibration The motionofabody aboutareferencepoint Atitssimplest, vibrationisdisplayed asdisplacementover time
Vibration Basics (Miller)
WhyUseVibrationAnalysis?
"Of all the parameters that can be measured non-intrusively in industry today, the one containing the most information on machinery health is the vibration signature."
Art Crawford Acknowledged expert in the field of vibration analysis
Vibration Basics (Miller)
OverallVersusSpectrum
Overallcanletyouknowthatthereisaproblem HeyFred,somethingiswrongwithyourcar!
Spectrumscantellyouwhattheproblemis HeyFred,yourwaterpumpisbad!
Vibration Basics (Miller)
TheUnits
Displacement accentuates thelowfrequencies Mils Acceleration accentuates thehigherfrequencies (gs) Velocity isconsistentacross alargerrangeof frequencies Mostvibrationis analyzedinVelocitysince theenergylevelis consistentthroughoutthe frequencyrange.
Vibration Basics (Miller) 7
Howdowemeasurevibration?
Threetypesofsensors Displacement,Velocity,Acceleration Signalprocessorofsometype(CSI2130) Localorportabledisplayforfieldanalysis Remote Softwareforviewingandstoringcollectedvibration data
Vibration Basics (Miller)
DisplacementProbes
TypicalApplications Sleevebearings Mostturbineandlargemotor drivenmachinery
Mainturbinegenerators Boilerfeedwaterpumps
ApplicationsinwhichXY dataisrequiredfor measurementssuchas
ShaftcenterlinefromDCgapdata Orbitsfromvibrationdata
Notpracticalforbearingorgearanalysis
Vibration Basics (Miller) 9
ElectromagneticInduction
Vibration Basics (Miller)
10
VelocityPickup
VelocitySensorApplication
Mountedoncaseofmachineorshaft
riders Usedonsleeveandrollerbearings dependingontheapplication Whenintegrationtodisplacementis required Hitemperature
Upto900Forhigher
Vibration Basics (Miller) 11
TheoryofOperation Velocity Pickups
Mechanical
Movingcoil Selfpowered Directional
Bobbin
Bobbin Spring
Pole
S
Magnet
Vibration Basics (Miller)
12
Accelerometer
AccelerometerApplications Casemountedormagnetmounted PrimarilyRollerelementBearingsandGears Whenanalysisanddiagnosticsareimportant
Vibration Basics (Miller)
13
Accelerometer
Amplifier Insulator Conductive Plate Insulator Preload Bolt Inertial Mass Piezoelectric Crystal
Vibration Basics (Miller)
14
Amplitude
Tim e
Amplitude
Amplitude
Tim e
y nc e u eq r F
Vibration Basics (Miller)
15
SignalProcessing TheMystery
1.5 1
0.5
Amplitude
Turning Speed
-0.5
-1
-1.5
Time
Turning Speed Time Waveform
Vibration Basics (Miller) 16
SignalProcessing
1.5 1
0.5
Amplitude
Turning Speed 2x TS
-0.5
-1
-1.5
Time
Add twice turning speed vibration
Vibration Basics (Miller) 17
SignalProcessing
1.5 1
Amplitude
0.5
Turning Speed 0 2x TS 7x TS
-0.5
-1
-1.5
Time
Add blade pass vibration
Vibration Basics (Miller) 18
SignalProcessing
1.5 1
Amplitude
0.5
Turning Speed 0 2x TS 7x TS Brg
-0.5
-1
-1.5
Time
Add Bearing Vibration
Vibration Basics (Miller) 19
SignalProcessing
Total Vibration
3
-1
-2
-3
Vibration Basics (Miller)
20
SignalProcessing breakdowncomplexwaveforminto waveformcomponents
The Fast Fourier Transform (FFT) takes the complex waveform and breaks it down into the component sine waves
3 1.5
0.5
FFT
-1
-0.5
-2
-1
-3
-1.5
The amplitudes for each sine wave is then plotted at the frequency of the sine wave, creating the Spectrum
Vibration Basics (Miller) 21
SignalProcessing TheFFTorSpectrum
Spectrum (FFT)
1.4 1.2
Twice Turning Speed Turning Speed
Amplitude
0.8
0.6
Blade Pass
0.4
Bearing Frequency
0.2
0 1 12 23 34 45 56 67 78 89 100 111 122 133 144 155 166 177 188 199 210 221 232 243 254 265 276 287 298 309 320 331 342 353 364 375 386 397
Frequency
Vibration Basics (Miller) 22
SoWhatcanVibrationAnalysisDetect?
DetectandTrackprogressingstagesofBearingFailure IdentifyImbalance andMisalignment
VibrationAnalysisisusedtocorrectImbalance
Identify/correctResonance IdentifyMechanicalWear incouplings,bearings,support
structures,etc.
Detectotherdefectssuchas:
Lubefailure/softfoot/brokenrotorbars Pumpcavitation,andmanymore
Vibration Basics (Miller)
23
WhatisaVibrationProgram?
Expertise,Technology,andWorkProcessesthat
PreventUnexpectedDowntime
Byassuringmachinesdonotfailcatastrophically
ExtendMachineLifeandOptimizePerformance
Bydetecting&correctingrootcauseconditionsthatcause excessivewear Do the right work
At the right time With the right methods
AllowYouToWorkEfficiently
Bytrendingprogressingfaultsand Coordinatingrepairstooccuratplannedoutages
Vibration Basics (Miller)
24
AFewCaseHistoriestoGetYouThinking
PaperMill:
Onlinevibrationmonitoringdetectedacrackedshaft
Presssection Trendincreaseddrasticallyover36hourperiod Wouldhaveotherwisefailedcatastrophically
OffshoreOilPlatform:
Onlinevibrationmonitoringsavescompressortwice!
Bearingproblemdetectedthroughvibrationanalysis. Bearingwasreplaced. Newfaultdetected6hourslater
Thermalexpansioncreatedbearingmisalignment
Vibration Basics (Miller)
25
A FewCaseHistoriestoGetYouThinking
CementMill:
Onlinevibrationmonitoringsolvesmystery Airhandlerwithintermittenthighvibration
Resonanceoccurswhenbaffleopenat~61%.
PowerPlant:
Onlinevibrationextendsmaintenanceintervals
Preventiveturbinemaintenanceevery5years Unnecessarymaintenancecaninducefaults! Extendfrom6 10yearswithonlinemonitoring Averagerepaircostaround$1million
Vibration Basics (Miller)
26
WhereShouldVibrationAnalysisbeUsed?
Plant Equipment
Predictive Criticaltoproduction Preventive Supportequipment Reactive Easy/Inexpensivetoreplace
Vibration Basics (Miller)
27
EstablishingaVibrationProgram
Defineprogramfocus/resources Determinecollectionmethod(s) Createdatabase Collectdata Detectdevelopingfaults Diagnosenatureandextentoffault Documentbusinessandmaintenanceimplications
Vibration Basics (Miller)
28
1)DefineProgramFocus
IdentifyCriticalMachines Effectonproduction Availabilityofbackupmachine Costtorepair Timetorepair DetermineResources Fullyinhousestaffed Fullyoutsourced Combination:Startup,Initialcontractservice,etc.
Vibration Basics (Miller)
29
2)DetermineCollection Method(s)
Routebasedperiodic Onlinemonitoring Generalplant Criticalequipment equipment Installedsensors Walkaroundsurvey Automaticmonitoring Manualmeasurement Definemeasurement Monthlyreadingtypical interval Readilyaccessible Inaccessibleor hazardousareas
Vibration Basics (Miller)
30
3)CreateDatabase
Entermachineconfigurationinformation MachineID(assetcode)andDescription MachineDesigninfo,OperatingSpeed,etc. Definemeasurementpoints
PointID(identification)andDescription SensorType(accelerometer) AnalysisParameters(howtoanalyzesignal) AlarmLimits(allowableamountofvibration)
Vibration Basics (Miller)
31
DataCollectionPoints Nomenclature
MOH MOP MOV MIH MIP MIV PIH PIP PIV POH POP POV
POA MOA
Standard: 2 vibration directions per bearing + 1 axial per shaft Add 1 PeakVue point per anti-friction bearing MOH = Motor Outboard Horizontal
Vibration Basics (Miller) 32
CollectData(Survey)
1) Periodicsurveywith walkaroundPortable Analyzer
2)Continuoussurveywith onlinemonitoring
Vibration Basics (Miller)
33
5)DetectDevelopingFaults
Visual detection using color and shape
Entire machine train on one screen
Vibration divided into frequency bands
Motor
Gearbox
Pump
34
Vibration Basics (Miller)
6)DiagnoseNatureofFault
Eachmachinefaultgeneratesaspecificvibration pattern(Bearings,Belts,etc.) Asinglevibrationmeasurementprovides informationaboutmultiplecomponents Thefrequencyofthevibrationisdeterminedby themachinedesignandoperatingspeed
Vibration Basics (Miller)
35
6)DiagnoseNatureofFault
Knowingtheaccurate machinespeedand phaseisimportant for vibrationanalysis.
Atachometerisrequiredtodeterminemachinespeed andphase.
Vibration Basics (Miller)
36
6)DiagnoseNatureofFault
Trend shows rate of advancement for fault in question
Individual trend parameter covers suspect frequency range
Vibration Basics (Miller)
37
SubHar monic 1X Amplitude
2X
Bearing Bearing
Gears
Bearing
1x Trend of Balance 5 mm/sec
2x
50x Trend of Bearings Alarm Time (Days)
Time (Days)
1 mm/sec
Alert and Fault alarms for each parameter
Vibration Basics (Miller) 38
6)DiagnoseNatureofFault
Imbalance typically appears at the turning speed of the machine
Imbalance
Vibration Basics (Miller)
39
6)DiagnoseNatureofFault
Misalignment typically shows up at either 1 or 2 x turning speed
Misalignment
Vibration Basics (Miller)
40
6)DiagnoseNatureofFault
Looseness shows up as multiples of turning speed
Looseness
Vibration Basics (Miller)
41
6)DiagnoseNatureofFault
Bearing wear shows up at specific peaks related to the geometry of the bearing and the speed of the shaft.
Bearing Wear
Vibration Basics (Miller)
42
RollerBearingFaults
Fourdifferentbearingfrequencies
Ball Spin Frequency (BSF) Fundamental Train Frequency (FTF) Ball Pass Frequency Inner Race (BPFI) Ball Pass Frequency Outer Race (BPFO)
Vibration Basics (Miller)
43
Specific peaks typically correlate to Specific machine faults Related to machine speed
Need Spectrum Analyzer for diagnostics, not just Overall vibration meter
Vibration Basics (Miller) 44
Advanced bearing wear shows up clearly in spectrum
Vibration Basics (Miller)
45
Early bearing wear frequently sometimes cant be detected with standard vibration measurements.
Vibration Basics (Miller)
46
Sidebands increase with gear wear
Many distinct peaks
Gear Wear
Vibration Basics (Miller)
47
ExamplesofOrbits
Misalignment, Resonance, Wear
Ellipse Truncation
Misalignment
Misalignment
Banana Inside ellipse
Shaft rub or mechanical looseness
Misalignment and other problems
Figure Eight Inner loop
Sub-synchronous whirl
Vibration Basics (Miller)
48
7) DocumentBusiness &MaintenanceImplications
Document:
Diagnoses Recommendations Accuracy Reoccurringfaults Productiongains Costsavings Financialimpact
Vibration Basics (Miller) 49
Summary:KeyPointsinaVibrationProgram
Expertise,Technology,andWorkProcessesthat
PreventUnexpectedDowntime
Byassuringmachinesdonotfailcatastrophically
ExtendMachineLifeandOptimizePerformance
Bydetecting&correctingrootcauseconditionsthatcause excessivewear
AllowYoutoWorkEfficiently
Bytrendingprogressingfaultsand Coordinatingrepairstooccuratplannedoutages
Vibration Basics (Miller)
50
