Post on 04-Oct-2015
description
02-12-14
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Imagination at work
Introduction to Vibration AnalysisPrograms as Part of a Predictive Maintenance StrategyEmad Bitar,Leader, Bently Supporting Services & Portables,
MEA, Turkey & Pakistan
Emad.Bitar@ge.com
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About me
Emad Bitar Emad.Bitar@ge.com
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 partscan 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
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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
Title or Job Number | XX Month 201X 10
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Library of more than 1 Million Bearings
Title or Job Number | XX Month 201X 11
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Criticality, Orientation and Support
Title or Job Number | XX Month 201X 12
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Multiple Bearings Option
Title or Job Number | XX Month 201X 13
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ISO or TA
Title or Job Number | XX Month 201X 14
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Title or Job Number | XX Month 201X 15
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Transducer Setup
Title or Job Number | XX Month 201X 16
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Spectra and Waveforms
Title or Job Number | XX Month 201X 17
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Measured Variables
Title or Job Number | XX Month 201X 18
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Setpoints / Alarms
Title or Job Number | XX Month 201X 19
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Automated Setup
Title or Job Number | XX Month 201X 20
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Copy / Paste
Title or Job Number | XX Month 201X 21
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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
Title or Job Number | XX Month 201X 24
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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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C anne ry M oto r - OE (left ) - H orizonta l - Acc F req 120 000 C PM18 /02 /200 0 8 :43:18
C PM
0 2 0,0 00 40 ,00 0 6 0,00 0 80 ,0 0 0 1 00 ,00 0 12 0,0 00
m/s
/s r
ms
0
0.2
0.4
0.6
0.8
1
1.2
O /All 3. 169 m /s /s rm s
Periodicity
Vibration is directional, so data must be taken in 3 directions:
Horizontal
Vertical
Axial
On every bearing
Typically once a month
Some machines require vbOnline system
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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
Data can be transferred using: High speed USB cables
Network connections
USB Memory Sticks
Ethernet
USB
Wireless LAN
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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 StructureColor Coded Structure
to indicate the
severity of the problem and its exact
location
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Title or Job Number | XX Month 201X 33
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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
Title or Job Number | XX Month 201X 36
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Machine
Title or Job Number | XX Month 201X 37
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Machine
Title or Job Number | XX Month 201X 38
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Component
Title or Job Number | XX Month 201X 39
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Bearing
Title or Job Number | XX Month 201X 40
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Measurement Location
Title or Job Number | XX Month 201X 41
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Pattern Recognition
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BasicTraining (4-6 months)
IntermediateTraining (1-2 years)
AdvancedTraining(> 3 years)
Training Courses
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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 AnalysisOrbit - Orbit Example - Side
7/26/2007 2:05:43 PM
mils (Horizontal)
-0.8 -0.6 -0.4-0.4 -0.2 0 0.2 0.4 0.6
mils
(V
ert
ical)
-0.6
-0.4-0.4
-0.2
0
0.2
0.4
0.6
7/26/2007 2:05:43 PM 3600 RPM
Filter: 1X .. 4X
Revolution: 1
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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
Title or Job Number | XX Month 201X 47
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Title or Job Number | XX Month 201X 48
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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???