Introduction to Vibration Analysis Program - Bnetly Nevada

02-12-14

1

Imagination at work

Introduction to Vibration AnalysisPrograms as Part of a Predictive Maintenance StrategyEmad Bitar,Leader, Bently Supporting Services & Portables,

MEA, Turkey & Pakistan

[email protected]

02-12-14

2

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

02-12-14

3

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?

02-12-14

4

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

02-12-14

5

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

02-12-14

6

Elements of a Vibration Analysis Program

System:

Hardware Data Collector / Analyzer

Software

People:

Personnel

Training

Process:

Workflow

Reports

Management:

Commitment

Funding

Monitoring

02-12-14

7

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

02-12-14

8

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

02-12-14

9

Steps of a Successful Vibration Analysis Program


2. Create database

3. Collect data

4. Detect problems




02-12-14

10

Machine Setup Made Easy: RPM

Title or Job Number | XX Month 201X 10

02-12-14

11

Library of more than 1 Million Bearings


02-12-14

12

Criticality, Orientation and Support


02-12-14

13

Multiple Bearings Option


02-12-14

14

ISO or TA


02-12-14

15


02-12-14

16

Transducer Setup


02-12-14

17

Spectra and Waveforms


02-12-14

18

Measured Variables


02-12-14

19

Setpoints / Alarms


02-12-14

20

Automated Setup


02-12-14

21

Copy / Paste


02-12-14

22

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

02-12-14

23

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

02-12-14

24

Route Setup


02-12-14

25

3. Data Collection

Routes that contain Machines and measurement points

are transferred to portable or online analyzers

02-12-14

26

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

02-12-14

27

Mounting the Sensor

Proper mounting is very important

Repeatability is

essential

Good mechanical transmission path from the bearing

02-12-14

28

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

02-12-14

29

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

02-12-14

30

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

02-12-14

31

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

02-12-14

32

Alarms in Database StructureColor Coded Structure

to indicate the

severity of the problem and its exact

location

02-12-14

33


02-12-14

34

Exception Report

02-12-14

35

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

02-12-14

36

Plant


02-12-14

37

Machine


02-12-14

38

Machine


02-12-14

39

Component


02-12-14

40

Bearing


02-12-14

41

Measurement Location


02-12-14

42

Pattern Recognition

02-12-14

43

BasicTraining (4-6 months)

IntermediateTraining (1-2 years)

AdvancedTraining(> 3 years)

Training Courses

02-12-14

44

Fault Frequencies

Special calculations are used to indicate where specific problems can be found on the spectrum called Fault Frequencies

02-12-14

45

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

02-12-14

46

Steps of a Vibration Program


2. Create database

3. Collect data

4. Detect problems




02-12-14

47

Generating Machine Diagnostic Report


02-12-14

48


02-12-14

49

Steps of a Vibration Program


2. Create database

3. Collect data

4. Detect problems




02-12-14

50

Key Points in a Successful Vibration Program

Trained and committed expertise

Intuitive Software and hardware

Committed management

Clear work process

02-12-14

51

Some of our customers

02-12-14

52

QUESTIONS???

Introduction to Vibration Analysis Program - Bnetly Nevada

Documents

Transcript of Introduction to Vibration Analysis Program - Bnetly Nevada