Introduction to Vibration Analysis Programs as Part of a Predictive Maintenance Strategy...
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Introduction to Vibration Analysis Programs as Part of a Predictive Maintenance Strategy Emad Bitar, Leader, Bently Supporting Services & Portables, MEA, Turkey & Pakistan
[email protected] Imagination at work
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About me… Emad Bitar
[email protected] More than 26 years of experience in Condition Monitoring Programs: Application Engineer / Application Manager Expertise in services, support, implementation and Training with more than 19 years in the Middle East Expertise in machinery troubleshooting using advanced vibration techniques Certified Trainer for advanced vibration , and Certification of Vibration Analyst I & II from the Vibration Institute (1994). Certified ISO Vibration Analysis CAT III. Wrote many technical papers for the Vibration Institute, PdM, Rotate, Uptime, Maintenance Management BS and MS in Mechanical Engineering from The University of Tennessee – USA
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Few things to start with… • Unplanned Downtime: – What does it do to your operation? – How often does it happen? – How much does it cost?
• Old Plant: – Are you trying to extend the life of your plant? – Are you trying to increase production with the same equipment?
• Maintenance: – What equipment needs maintenance next? – Can we skip this outage and run for few more months?
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Many Technologies… One Answer • Vibration measurement contains information from the machine and its surrounding • Every problem on a machine has a distinct vibration behavior • Any changes in the vibration signature indicate there are changes in the dynamic condition of the machine
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Many Problems… One Technology •Imbalance, Misalignment and Resonance can be detected and corrected •Bearing defects can be tracked through its various stages •The severity of gear problems can be identified without stopping the machine •Wears in mechanical and structural parts can be distinctly identified and corrected •Electrical problems in motors shows up in the vibration waveform and spectrum •Lubrication problems produce friction and impacting with distinctive vibration behaviors •Other problems like cavitations in pump, soft foot, and belt problems and others can be trended and diagnosed
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Elements of a Vibration Analysis Program System: • Hardware – Data Collector / Analyzer • Software
People: • Personnel • Training
Process: • Workflow • Reports
Management: • Commitment • Funding • Monitoring
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Steps of a Successful Vibration Analysis Program 1. Gather machine information 2. Create database 3. Collect data 4. Detect problems 5. Analyze the nature and the severity of problems 6. Generate reports on equipment status 7. Follow up on findings
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Machine Information •Shaft speed •Bearing types •Gearbox design and number of teeth •Belt lengths and pulleys diameters •Motor load and number of bars •Coupling type •Number of vanes or blades •Measurement locations and directions •Sensors type and sensitivity 8
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Steps of a Successful Vibration Analysis Program 1. Gather machine information 2. Create database 3. Collect data 4. Detect problems 5. Analyze the nature and the severity of problems 6. Generate reports on equipment status 7. Follow up on findings
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Machine Setup Made Easy: RPM
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Library of more than 1 Million Bearings
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Criticality, Orientation and Support
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Multiple Bearings Option
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ISO or TA
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Transducer Setup
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Spectra and Waveforms
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Measured Variables
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Setpoints / Alarms
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Automated Setup
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Copy / Paste
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Database Setup Results • Without any vibration knowledge, the machine has been setup quickly with the use of normal machine information readily available in the maintenance library • All the alarm limits, analysis parameter sets and fault frequencies are easily setup with the machine • After just few steps, you are ready to collect data and do analysis
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Create Routes • Locate machines to be monitored in plant • List of machines and measurement points • Choose logical order for data collection of machines and points • Do a cold walkthrough to locate the machines and modify the order to suite the actual locations • A different route may be created for each section of the plant • A machine may be on multiple routes
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Route Setup
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3. Data Collection Routes that contain Machines and measurement points are transferred to portable or online analyzers
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Sensor Selection The sensor converts the vibration into an electronic signal The most common sensor is an accelerometer The sensor is commonly attached using a magnet Other vibration sensors: – Velocity Pickup – Displacement
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Mounting the Sensor
Proper mounting is very important “Repeatability” is essential Good “mechanical transmission path” from the bearing
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Repeatability • Vibration changes when the speed and load change • The machine must operate in the same state during every test • Check the speed and load with each measurement • Collect data in the same location, direction and methodology every time • Best Option - collecting data from permanently installed sensors
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Periodicity Vibration is directional, so data must be taken in 3 directions: • Horizontal • Vertical • Axial
On every bearing Typically once a month C anne ry M oto r - O E (left ) - H orizonta l - Ac c F req 120 000 C PM 18 /02 /200 0 8 :43: 18 O /A ll 3. 169 m /s /s rm s
1.2
1
0.8
m/s/s rms
Some machines require vbOnline system
0.6
0.4
0.2
0 0
2 0,0 00
40 ,00 0
6 0,00 0 C PM
80 ,0 0 0
1 00 ,00 0
12 0,0 00
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Transfer Data to the Database Captured data on every point is stamped with time and date All data on the route and off-route is transferred to the database
USB
Data can be transferred using: • High speed USB cables • Network connections
Ethernet Wireless LAN
• USB Memory Sticks
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4. Problem Detection Vibration levels on every Analysis Parameter on every point are automatically checked against its corresponding alarm Limits Exception Report generates a list of machines and measurement points that only exceed the pre-set alarm levels
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Alarms in Database Structure
Color Coded Structure to indicate the severity of the problem and its exact location
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Exception Report
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5. Diagnose Nature and Severity of Faults • Every Mechanical, Electrical or Structural fault has a distinct vibration behavior • Any changes in the vibration signature indicate changes in the dynamic condition of the machine • A single vibration measurement provides information the machine and its surrounding structure and other machinery
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Plant
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Machine
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Machine
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Component
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Bearing
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Measurement Location
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Pattern Recognition
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Training Courses
Advanced Training (> 3 years)
Intermediate Training (1-2 years)
Basic Training (4-6 months)
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Fault Frequencies Special calculations are used to indicate where specific problems can be found on the spectrum – called “Fault Frequencies”
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Advanced Analysis Orbit - Orbit Example - Side 7/26/2007 2:05:43 PM Filter: 1X .. 4X Revolution: 1 0.6
0.4
mils (Vertical)
0.2
0
-0.2
-0.4
-0.6
-0.8
7/26/2007 2:05:43 PM
-0.6
-0.4
-0.2
0 mils (Horizontal)
0.2
0.4
0.6
3600 RPM
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Steps of a Vibration Program 1. Gather machine information 2. Create database 3. Collect data 4. Detect problems 5. Analyze the nature and the severity of problems 6. Generate reports on equipment status 7. Follow up on findings
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Generating Machine Diagnostic Report
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Steps of a Vibration Program 1. Gather machine information 2. Create database 3. Collect data 4. Detect problems 5. Analyze the nature and the severity of problems 6. Generate reports on equipment status 7. Follow up on findings
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Key Points in a Successful Vibration Program • Trained and committed expertise • Intuitive Software and hardware • Committed management • Clear work process
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Some of our customers…
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QUESTIONS??? 52
