Vibration Monitoring

CSI 4500 Machinery Health Monitor Overview Jon Hall Novaspect, Inc.

Failure Curve Infant Mortality

Expected Life

End of Life

Probability of Failure

Protection System

Time

Failure Curve Infant Mortality

Expected Life

Probability of Failure

Predictive System

End of Life Protection System

Failure

sion s e r og lt Pr u a F

Time

Control Room Online Watch

Maintenance Engineering AMS Machinery Online Watch Manager

PDM Group AMS Machinery Manager

Plant Network

MHM Server Dedicated Ethernet

JBOX

JBOX

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Control Room Online Watch

Maintenance Engineering AMS Machinery Online Watch Manager

PDM Group AMS Machinery Manager

Plant Network

MHM Server Dedicated Ethernet

JBOX

JBOX

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Why Online/Continuous Monitoring z z

Critical Equipment Hard to Access – Distance – Safety

z z

Man Power Repeatability

Protection System z z

z

Normally based on overall vibration levels Designed to prevent additional damage after failure REACTIVE

Predictive System z z

z z

Identifies faults prior to failures. Allows for planning to repair fault, or correct a condition that will lead to a fault. Allows user to track the progression of faults PROACTIVE

Machinery Applications in a Typical Plant Total # Machines 2,500 Typical Industrial Process Plant

Turbines Generators Compressors

Motors Pumps Fans Gears

~125 Machines

~625 Machines

5% Critical

25% Essential

Online Monitoring

CSI 4500 Monitor

Loss of machine means > 40% lost plant capacity

CSI 9210 Transmitter

Automated Data Collection Periodic Data Collection

~750 Machines

~500 Machines ~500 Machines

30% Important

20% Secondary 20% Non-Essential

Portable Portable

CSI 2130 Analyzer

Run to Fail

Introduction to vibration z

z

Vibration – The motion of a body about a reference point At it’s simplest, vibration is displayed as displacement over time, in Mils.

Simple Vibration at 60 Hz - Displacement 1.5

Period 1

0.5

Displacement 60Hz

0

-0.5

-1

Amplitude -1.5

Freq= 1/Period

Velocity at 180 Hz 1.5

1

0.5

0

-0.5

-1

-1.5

Displacement 180Hz Velocity 180 Hz

Acceleration – Rate of Change of Velocity 1.5

1

0.5

Displacement 60Hz 0

Velocity 60 Hz Acceleration 60Hz

-0.5

-1

-1.5

The units z

z

z

z

Displacement accentuates the low frequencies - Mils Acceleration accentuates the higher frequencies (g’s) Velocity is consistent across all frequencies (in/sec or mm/sec) Most vibration is analyzed in Velocity

Types of Data – Time Waveform 1.5

1

0.5

Turning Speed

0

-0.5

-1

-1.5

Turning Speed Time Waveform

Types of Data – Time Waveform 1.5

1

0.5

Turning Speed

0

2x TS

-0.5

-1

-1.5

Add twice turning speed vibration

Types of Data – Time Waveform 1.5

1

0.5

Turning Speed 2x TS

0

7x TS

-0.5

-1

-1.5

Add blade pass vibration

Types of Data – Time Waveform 1.5

1

0.5

Turning Speed 2x TS

0

7x TS Brg

-0.5

-1

-1.5

Add Bearing Vibration

Types of Data – Time Waveform Total Vibration 3

2

1

0

Total Vibration

-1

-2

-3

Complex Time Waveform

If all machines are frequency generators, Then what components would I expect to see?

If all machines are frequency generators, Then what components would I expect to see?

Collection of Data … Data… What would I expect to see?

Component

Frequency RPM

Hz ( / 60)

Orders (Motor Speed)

1800 720 900 4 x 900

30 12 15 4 x 15

1.0 0.4 0.5 4 x 0.5

1. BPFI

10,638

177.3

5.91

2. BPFO

7,362

122.7

4.09

3. BSF

4,752

79.2

2.64

4. Cage

736

12.3

0.409

Structure

420

7

0.23

Motor Belts Fan Shaft Fan Blades Roller Brgs

Collection of Data … Data… What would I expect to see?

Component

Frequency RPM

Hz ( / 60)

Orders (Motor Speed)

1800 720 900 4 x 900

30 12 15 4 x 15

1.0 0.4 0.5 4 x 0.5

1. BPFI

10,638

177.3

5.91

2. BPFO

7,362

122.7

4.09

3. BSF

4,752

79.2

2.64

4. Cage

736

12.3

0.409

Structure

420

7

0.23

Motor Belts Fan Shaft Fan Blades Roller Brgs

A Typical Waveform

Need Spectrum Analyzer for diagnostics, not just Overall vibration meter

Types of Data - Spectrum z

z

The complex time waveform is difficult to analyze. A Fourier transform is performed on the waveform to put the data is a format that is easier to understand,

3

2

1

0

-1

-2

-3

Complex Time Waveform

Types of Data - Spectrum The Fast Fourier Transform (FFT) takes the complex waveform and breaks it down into the component sine waves 3

1.5

2

1

1

0.5

0

FFT

0

-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 Spectum

Spectrum (Fast Fourier Transform) Spectrum (FFT) 1.4

Twice Turning Speed

1.2

Turning Speed 1

0.8

0.6

Blade Pass 0.4

Bearing Frequency 0.2

397

386

375

364

353

342

331

320

309

298

287

276

265

254

243

232

221

210

199

188

177

166

155

144

133

122

111

89

100

78

67

56

45

34

23

1

12

0

Industrial equipment have numerous sources of vibration, all of which will be included in the spectrum and waveform.

Lake - Cooling Tower #1 Fan Motor CT1 -M1A Motor Outboard Axial

0.08 0.07

Route Spectrum 02-Jul-04 10:03:14 OVERALL= .1344 V-DG PK = .1341 LOAD = 100.0 RPM = 1757. (29.29 H

0.06 0.05 0.04 0.03 0.02 0.01 0 0

10

20

30 40 50 60 Frequency in Orders

70

1.0 Acceleration in G-s

z

PK Velocity in In/Sec

Actual Spectra & Waveform

80

Route Waveform 02-Jul-04 10:03:14 RMS = .2551 PK(+/-) = .8398/.9374 CRESTF= 3.67

0.5 0 -0.5 -1.0 -1.5 0

30

60

90 120 Time in mSecs

150

180

Signal Acquisition/Processing Transducer Amplitude

Overall Energy

Waveform

Time

FFT Spectrum Amplitude Frequency

FFT = Fast Fourier Transform

Sources of Vibration z

Simplest Rotating Machine – Mass spinning on an axis

Sources of Vibration z

Imbalance – Center of Mass is not the Center of rotation

Heavy Spot

Sources of Vibration z

Misalignment – Two Masses spinning on a coupled axis

Sources of Vibration z

Rolling Element Bearing

Sources of Vibration z

Rolling Element Bearing

Sources of Vibration Fundamental Train (FTF) = S/2 x(1-Bd/Pd x cosθ) Inner Race (BPFI) = Nb/2 x S x (1+Bd/Pd x cosθ) Outer Race (BPFO) = Nb/2 x S x (1-Bd/Pd x cosθ) Roller Pass (BSF)=Pd/2BdxSx[1-(Bd/Pd)2 x (cosθ)2 S = Speed Bd = Roller Diameter Nb = Number of Rollers Pd = Pitch Diameters Θ = Contact Angle

Sources of Vibration z

Flow Related – Vane Pass – Blade Pass

Sources of Vibration z

Gear Vibration – Gearmesh = # Teeth x turning speed – Shaft speeds

Sources of Vibration z

Structural – Looseness – Resonance

Measuring Vibration z

Three common types of sensors that measure the three components of vibration: – Displacement Probes – Velocity Probes – Accelerometers

Measuring Vibration z

z

z

Sensors can be permanently or temporarily mounted Bolted to equipment, connected with adhesive, or magnets Sensors can be connected to portable equipment or continuous monitoring systems.

Example of an Accelerometer on a Pump

Example of a Displacement Probe on a Turbine Bearing

Proximity Probe

Accelerometer

Types of Vibration Data z z z

Monitoring Overall Vibration Parameter Banding, Alarms and Trending Spectral Analysis

Types of data – Overall Vibration 1.2

1

0.8

0.6

0.4

0.2

397

386

375

364

353

342

331

320

309

298

287

276

265

254

243

232

221

210

199

188

177

166

155

144

133

122

89

111

78

100

67

56

45

34

0 1

It includes all vibration in the spectrum or waveform (depending on the type of overall) and is independent of frequency

Spectrum (FFT) 1.4

23

z

Overall Vibration is the sum total of all vibration measured

12

z

Total Vibration 3

2

1

0

-1

-2

-3

Total Vibration

1.2

1

1

0.8

0.8

Amplitude

1.2

0.6

0.6

0.4

0.4

Bearing Defect

Frequency

Overall Vibration 11.7

397

385

373

361

349

337

325

313

301

289

277

265

253

241

229

217

205

193

181

169

157

145

133

121

97

109

85

73

61

49

0 37

0 25

0.2

1

0.2

13

Amplitude

Overall Vibration Levels

1

14 27 40 53 66 79 92 105 118 131 144 157 170 183 196 209 222 235 248 261 274 287 300 313 326 339 352 365 378 391 Frequency

Overall Vibration 12.0

Overall Monitoring Instruments z

Benefits – Easy to use – Gives an empirical indication of overall condition

z

Limitations – Unable to isolate background vibration – Unable to identify sources of vibration – Detection is limited to late stage faults

Band 1

1 2 3 4 5 6 7

397

386

375

364

353

342

331

320

309

298

287

276

265

254

243

232

221

210

199

188

177

166

155

144

133

122

111

100

89

78

67

56

45

34

23

12

Parameter Banding/Alarming Spectrum (FFT)

1.4

1.2

1

0.8

0.6

0.4

0.2

0

Band 1

1 2 3 4 5 6 7

397

386

375

364

353

342

331

320

309

298

287

276

265

254

243

232

221

210

199

188

177

166

155

144

133

122

111

100

89

78

67

Inner Race

Outer Race

Electrical

Misalignment

1

56

45

Imbalance

1.2

34

1.4

23

12

Parameter Banding/Alarming Spectrum (FFT)

0.8

0.6

0.4

0.2

0

Spectral Analysis A2 - Tending Side Brg(Outer Race) TSBRG -R1H ROLL BRG. #1 - HORIZONTAL

PK Velocity in In/Sec

0.024

Route Spectrum 07-Jun-96 12:26:02 OVERALL= .0584 V-DG PK = .0608 LOAD = 100.0 FPM = 10669. (383. RPM)

0.020 0.016 0.012 0.008 0.004 0 0

100

200 300 Frequency in Hz

400

Acceleration in G-s

0.3

500

Route Waveform 07-Jun-96 12:26:02 RMS = .0615 PK(+/-) = .2060/.1977 CRESTF= 3.35

0.2 0.1 0.0 -0.1 -0.2 -0.3 0

200

400

600 Time in mSecs

800

1000

Spectral Analysis A2 - Tending Side Brg(Outer Race) TSBRG -R1H ROLL BRG. #1 - HORIZONTAL

PK Velocity in In/Sec

0.024 C

0.020

C

C

C

Route Spectrum 07-Jun-96 12:26:02 OVERALL= .0584 V-DG PK = .0608 LOAD = 100.0 FPM = 10669. (383. RPM) >TMK 688TD C=BPFO: 65.38

C

0.016 0.012 0.008 0.004 0 0

100

200 300 Frequency in Hz

400

Acceleration in G-s

0.3

500

Route Waveform 07-Jun-96 12:26:02 RMS = .0615 PK(+/-) = .2060/.1977 CRESTF= 3.35

0.2 0.1 0.0 -0.1 -0.2 -0.3 0

200

400

600 Time in mSecs

800

1000

Spectral Analysis z

Benefits – Identify faults – Determine severity

z

Limitations – Time consuming – Requires training and experience

A balance of technology z z

z

z

Baseline all equipment with Spectral Analysis Use parameter banding and trending as a screening tool Only do detailed analysis on equipment with alarms or increasing trends Use overall vibration as a trip setting

CSI 4500 Machinery Health Monitor Technical Details

16 Tach Channels 1x Peak and Phase - PulsePulse-type speed inputs - Frequency divider - Adaptive tach feature - autoauto-locks on speed

32 Sensor monitors

Alerts in less than 100mSec - Accelerometers - Velocity probes - Displacement probes - AC signal - Flux/Dynamic pressure - DC signal - Temperature/Load

Processor / Comm 16 Digital I/O - Input and outputs - OPTOTM relay modules

- Ethernet HUB and NIC - 1 Predictive Processor - 1 Processor feeding live updates - Up to 32 Mb memory - New Local Display

Aux Power +/+/- 24 Vdc (Displacement probes) Unit Input Power 24 Vdc OR

110 / 220 VAC

CSI 4500 Machinery Health Monitor Technical Details z

Uses all three levels of vibration analysis – Gross Scan (Overall) – Parameter banding, trending and alarming – Spectrum and waveform

z

You determine the conditions under which data is collected and how often it is stored.

CSI 4500 Machinery Health Monitor Technical Details z

12, 16, and 32 analog input channels available

CSI 4500 Machinery Health Monitor Technical Details Control Room Online Watch

Plant Control System

Maintenance Engineering AMS Machinery Online Watch Manager

Plant Network

Common Server for MHM Online and LAN Software

MHM Server Dedicated Ethernet (or wireless) provided by customer

Digital I/O to DCS

JBOX JBOX

JBOX

JBOX

Boiler Feed Water Pumps Option 1 Option 2 8 Proximity 5 Accelerometers Probes and one and one tachometer per tachometer per pump pump

Cooling Water Pumps 5 Accelerometers and one Tachometer per pump

JBOX

PDM Group AMS Machinery Manager

4500 Connectivity AMS Asset Portal

Other Control Systems

XML*

Operations

Maintenance AMS Device Manager

AMS Machinery Manager

Ethernet

CSI 4500 Machinery Health Monitor

Critical Machinery

CSI 4500 Machinery Health Monitor Technical Details z

Predicate based data collection Speed

Analog Input

Digital I/O

Predicate Based Data Collection Overall Vibration 1.2 1

Amplitude

0.8 0.6 0.4 0.2 0 1

2

3

4

5

6

7

8

9

10 11 12 13

Time

14 15 16 17 18

Predicate Based Data Collection Overall Vibration w/ RPM 4000

1.2

3500

1

3000 0.8

RPM

2500

0.6

2000 1500

0.4

1000 0.2

500 0

0 1

2

3

4

5

6

7

8

9 10 11 12 13 14 15 16 17 18 Time

RPM Overall

Predicate Based Data Collection Overall Value by Speed 1.2 High Speed Alarm

1

Amplitude

0.8 High speed

0.6 Low Speed Alarm

0.4 0.2 0 1

2

3

4

5

6

7

8

9 10 11 12 13 14 15 16 17 18 Time

Low Speed

Failure Curve Infant Mortality

Expected Life

Probability of Failure

Predictive System

End of Life Protection System

Failure

sion s e r og lt Pr u a F

Time

Machinery Applications in a Typical Plant Total # Machines 2,500 Typical Industrial Process Plant

Turbines Generators Compressors

Motors Pumps Fans Gears

~125 Machines

~625 Machines

5% Critical

25% Essential

Online Monitoring

CSI 4500 Monitor

Loss of machine means > 40% lost plant capacity

CSI 9210 Transmitter

Automated Data Collection Periodic Data Collection

~750 Machines

~500 Machines ~500 Machines

30% Important

20% Secondary 20% Non-Essential

Portable Portable

CSI 2130 Analyzer

Run to Fail

Installed Systems & Applications Summary of Customers by Industry

Questions??