53512817 vibration monitoring
TRANSCRIPT
CSI 4500 Machinery CSI 4500 Machinery Health Monitor OverviewHealth Monitor OverviewJon HallNovaspect, Inc.
Failure CurveFailure CurveFailure CurvePr
obab
ility
of F
ailu
re
Time
Infant Mortality Expected Life End of Life
Protection System
Failure CurveFailure CurveFailure CurvePr
obab
ility
of F
ailu
re
Time
Infant Mortality Expected Life End of Life
Failure
Fault Progression
Predictive System Protection System
JBOX JBOX
JBOX
JBOXJBOX
JBOX
JBOX
JBOX JBOX
JBOX
MHMServer
Control RoomOnline Watch
EngineeringOnline Watch
PDM GroupAMS Machinery
Manager
MaintenanceAMS Machinery
Manager
Dedicated Ethernet
Plant Network
JBOX JBOX
JBOX
JBOXJBOX
JBOX
JBOX
JBOX JBOX
JBOX
MHMServer
Control RoomOnline Watch
EngineeringOnline Watch
PDM GroupAMS Machinery
Manager
MaintenanceAMS Machinery
Manager
Dedicated Ethernet
Plant Network
Why Online/Continuous MonitoringWhy Online/Continuous MonitoringWhy Online/Continuous MonitoringCritical EquipmentHard to Access– Distance– Safety
Man PowerRepeatability
Protection SystemProtection SystemProtection SystemNormally based on overall vibration levelsDesigned to prevent additional damage after failureREACTIVE
Predictive SystemPredictive SystemPredictive SystemIdentifies 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 faultsPROACTIVE
Machinery Applications in a Typical PlantMachinery Applications Machinery Applications in a Typical Plantin a Typical Plant
Online Monitoring
Portable
~125 Machines
~625 Machines
~500 Machines
~500 Machines
Total # Machines 2,500Typical Industrial Process Plant
5%5%CriticalCritical
25%25%EssentialEssential
30%30%ImportantImportant
20%20%SecondarySecondary
20%20%NonNon--EssentialEssential
TurbinesGenerators
Compressors
MotorsPumps
FansGears
Run to Fail
Portable
Automated Data CollectionPeriodic Data Collection
CSI 4500 Monitor
CSI 9210Transmitter
Loss of machine meansLoss of machine means> 40% lost plant capacity> 40% lost plant capacity
CSI 2130Analyzer
~750 Machines
Introduction to vibrationIntroduction to vibrationIntroduction to vibrationVibration – 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 - DisplacementSimple Vibration at 60 Hz Simple Vibration at 60 Hz -- DisplacementDisplacement
-1.5
-1
-0.5
0
0.5
1
1.5
Displacement 60Hz
Amplitude
Period
Freq= 1/Period
Velocity at 180 HzVelocity at 180 HzVelocity at 180 Hz
-1.5
-1
-0.5
0
0.5
1
1.5
Displacement 180HzVelocity 180 Hz
Acceleration – Rate of Change of VelocityAcceleration Acceleration –– Rate of Change of VelocityRate of Change of Velocity
-1.5
-1
-0.5
0
0.5
1
1.5
Displacement 60HzVelocity 60 HzAcceleration 60Hz
The unitsThe unitsThe unitsDisplacement accentuates the low frequencies - MilsAcceleration 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 WaveformTypes of Data Types of Data –– Time WaveformTime Waveform
-1.5
-1
-0.5
0
0.5
1
1.5
Turning Speed
Turning Speed Time Waveform
Types of Data – Time WaveformTypes of Data Types of Data –– Time WaveformTime Waveform
Add twice turning speed vibration
-1.5
-1
-0.5
0
0.5
1
1.5
Turning Speed2x TS
Types of Data – Time WaveformTypes of Data Types of Data –– Time WaveformTime Waveform
Add blade pass vibration
-1.5
-1
-0.5
0
0.5
1
1.5
Turning Speed2x TS7x TS
Types of Data – Time WaveformTypes of Data Types of Data –– Time WaveformTime Waveform
Add Bearing Vibration
-1.5
-1
-0.5
0
0.5
1
1.5
Turning Speed2x TS7x TSBrg
Total Vibration
-3
-2
-1
0
1
2
3
Total Vibration
Types of Data – Time WaveformTypes of Data Types of Data –– Time WaveformTime Waveform
Complex Time Waveform
If all machines are frequency generators,Then what components would I expect to see?If all machines are frequency generators,If all machines are frequency generators,Then what components would I expect to see?Then what components would I expect to see?
If all machines are frequency generators,Then what components would I expect to see?If all machines are frequency generators,If all machines are frequency generators,Then what components would I expect to see?Then what components would I expect to see?
Collection of Data…What would I expect to see?Collection of DataCollection of Data……What would I expect to see?What would I expect to see?
Component FrequencyRPM Hz Orders
( / 60) (Motor Speed)Motor 1800 30 1.0Belts 720 12 0.4Fan Shaft 900 15 0.5Fan Blades 4 x 900 4 x 15 4 x 0.5Roller Brgs 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 0.409Structure 420 7 0.23
Collection of Data…What would I expect to see?Collection of DataCollection of Data……What would I expect to see?What would I expect to see?
Component FrequencyRPM Hz Orders
( / 60) (Motor Speed)Motor 1800 30 1.0Belts 720 12 0.4Fan Shaft 900 15 0.5Fan Blades 4 x 900 4 x 15 4 x 0.5Roller Brgs 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 0.409Structure 420 7 0.23
A Typical WaveformA Typical WaveformA Typical Waveform
Need Spectrum Analyzer for diagnostics, not just Overall vibration meter
Types of Data - SpectrumTypes of Data Types of Data -- SpectrumSpectrumThe 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 - SpectrumTypes of Data Types of Data -- SpectrumSpectrum
-3
-2
-1
0
1
2
3
-1.5
-1
-0.5
0
0.5
1
1.5
The Fast Fourier Transform (FFT) takes the complex waveform and breaks it down into the component sine waves
FFT
The amplitudes for each sine wave is then plotted at the frequency of the sine wave, creating the Spectum
Spectrum (Fast Fourier Transform)Spectrum (Fast Fourier Transform)Spectrum (Fast Fourier Transform)Spectrum (FFT)
0
0.2
0.4
0.6
0.8
1
1.2
1.4
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
Turning Speed
Twice Turning Speed
Bearing Frequency
Blade Pass
Actual Spectra & WaveformActual Spectra & WaveformActual Spectra & WaveformIndustrial equipment have numerous sources of vibration, all of which will be included in the spectrum and waveform.
Lake - Cooling Tower #1 Fan MotorCT1 -M1A Motor Outboard Axial
Route Spectrum 02-Jul-04 10:03:14 OVERALL= .1344 V-DG PK = .1341 LOAD = 100.0 RPM = 1757. (29.29 H
0 10 20 30 40 50 60 70 80
0 0.010.020.030.040.050.060.070.08
Frequency in Orders
PK V
eloc
ity in
In/S
ec
Route Waveform 02-Jul-04 10:03:14 RMS = .2551 PK(+/-) = .8398/.9374 CRESTF= 3.67
0 30 60 90 120 150 180
-1.5
-1.0
-0.5
0
0.5
1.0
Time in mSecs
Acc
eler
atio
n in
G-s
Signal Acquisition/ProcessingSignal Acquisition/ProcessingSignal Acquisition/ProcessingTransducer
Overall Energy
FFT
Waveform
SpectrumA
mplitude
Am
plitude
Time
Frequency
FFT = Fast Fourier TransformFFT = Fast Fourier Transform
Sources of VibrationSources of VibrationSources of VibrationSimplest Rotating Machine– Mass spinning on an axis
Sources of VibrationSources of VibrationSources of VibrationImbalance– Center of Mass is not the
Center of rotation
Heavy Spot
Sources of VibrationSources of VibrationSources of VibrationMisalignment– Two Masses spinning on a coupled axis
Sources of VibrationSources of VibrationSources of VibrationRolling Element Bearing
Sources of VibrationSources of VibrationSources of VibrationRolling Element Bearing
Sources of VibrationSources of VibrationSources of VibrationFundamental 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 = SpeedBd = Roller DiameterNb = Number of RollersPd = Pitch DiametersΘ = Contact Angle
Sources of VibrationSources of VibrationSources of VibrationFlow Related– Vane Pass– Blade Pass
Sources of VibrationSources of VibrationSources of VibrationGear Vibration– Gearmesh = # Teeth x
turning speed– Shaft speeds
Sources of VibrationSources of VibrationSources of VibrationStructural– Looseness– Resonance
Measuring VibrationMeasuring VibrationMeasuring VibrationThree common types of sensors that measure the three components of vibration:– Displacement Probes – Velocity Probes– Accelerometers
Measuring VibrationMeasuring VibrationMeasuring VibrationSensors can be permanently or temporarily mountedBolted to equipment, connected with adhesive, or magnetsSensors can be connected to portable equipment or continuous monitoring systems.
Example of an Accelerometer on a PumpExample of an Accelerometer on a Example of an Accelerometer on a PumpPump
Example of a Displacement Probe on a Turbine BearingExample of a Displacement Probe on a Example of a Displacement Probe on a Turbine BearingTurbine Bearing
Proximity ProbeProximity ProbeProximity Probe
AccelerometerAccelerometerAccelerometer
Types of Vibration DataTypes of Vibration DataTypes of Vibration DataMonitoring Overall VibrationParameter Banding, Alarms and TrendingSpectral Analysis
Types of data – Overall VibrationTypes of data Types of data –– Overall VibrationOverall VibrationOverall Vibration is the sum total of all vibration measuredIt includes all vibration in the spectrum or waveform (depending on the type of overall) and is independent of frequency
Spectrum (FFT)
0
0.2
0.4
0.6
0.8
1
1.2
1.4
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
Total Vibration
-3
-2
-1
0
1
2
3
Total Vibration
Overall Vibration LevelsOverall Vibration LevelsOverall Vibration Levels
0
0.2
0.4
0.6
0.8
1
1.2
1 13 25 37 49 61 73 85 97 109
121
133
145
157
169
181
193
205
217
229
241
253
265
277
289
301
313
325
337
349
361
373
385
397
Frequency
Am
plitu
de
0
0.2
0.4
0.6
0.8
1
1.2
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
FrequencyA
mpl
itude
Overall Vibration 11.7 Overall Vibration 12.0
Bearing Defect
Overall Monitoring InstrumentsOverall Monitoring InstrumentsOverall Monitoring InstrumentsBenefits– Easy to use– Gives an empirical indication of overall condition
Limitations– Unable to isolate background vibration– Unable to identify sources of vibration– Detection is limited to late stage faults
Parameter Banding/AlarmingParameter Banding/AlarmingParameter Banding/AlarmingSpectrum (FFT)
0
0.2
0.4
0.6
0.8
1
1.2
1.4
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
Band 1 2 3 4 5 6 7
Parameter Banding/AlarmingParameter Banding/AlarmingParameter Banding/AlarmingSpectrum (FFT)
0
0.2
0.4
0.6
0.8
1
1.2
1.4
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
Band 1 2 3 4 5 6 7
Imba
lanc
e
Mis
alig
nmen
t
Elec
trica
l
Out
er R
ace
Inne
r Rac
e
Spectral AnalysisSpectral AnalysisSpectral Analysis
Route Waveform 07-Jun-96 12:26:02 RMS = .0615 PK(+/-) = .2060/.1977 CRESTF= 3.35
0 200 400 600 800 1000
-0.3
-0.2
-0.1
0.0
0.1
0.2
0.3
Time in mSecs
Acc
eler
atio
n in
G-s
A2 - Tending Side Brg(Outer Race)TSBRG -R1H ROLL BRG. #1 - HORIZONTAL
Route Spectrum 07-Jun-96 12:26:02 OVERALL= .0584 V-DG PK = .0608 LOAD = 100.0 FPM = 10669. (383. RPM)
0 100 200 300 400 500
0
0.004
0.008
0.012
0.016
0.020
0.024
Frequency in Hz
PK V
eloc
ity in
In/S
ec
Spectral AnalysisSpectral AnalysisSpectral Analysis
Route Waveform 07-Jun-96 12:26:02 RMS = .0615 PK(+/-) = .2060/.1977 CRESTF= 3.35
0 200 400 600 800 1000
-0.3
-0.2
-0.1
0.0
0.1
0.2
0.3
Time in mSecs
Acc
eler
atio
n in
G-s
A2 - Tending Side Brg(Outer Race)TSBRG -R1H ROLL BRG. #1 - HORIZONTAL
Route Spectrum 07-Jun-96 12:26:02 OVERALL= .0584 V-DG PK = .0608 LOAD = 100.0 FPM = 10669. (383. RPM)
0 100 200 300 400 500
0
0.004
0.008
0.012
0.016
0.020
0.024
Frequency in Hz
PK V
eloc
ity in
In/S
ec
>TMK 688TD C=BPFO: 65.38
C C C C C
Spectral AnalysisSpectral AnalysisSpectral AnalysisBenefits– Identify faults– Determine severity
Limitations– Time consuming– Requires training and experience
A balance of technologyA balance of technologyA balance of technologyBaseline all equipment with Spectral AnalysisUse parameter banding and trending as a screening toolOnly do detailed analysis on equipment with alarms or increasing trendsUse overall vibration as a trip setting
CSI 4500 Machinery Health MonitorTechnical DetailsCSI 4500 Machinery Health MonitorCSI 4500 Machinery Health MonitorTechnical DetailsTechnical Details
32 Sensor monitors32 Sensor monitorsAlerts in less than 100mSec -- AccelerometersAccelerometers-- Velocity probesVelocity probes-- Displacement probesDisplacement probes-- AC signalAC signal
-- Flux/Dynamic pressureFlux/Dynamic pressure-- DC signalDC signal
-- Temperature/LoadTemperature/Load
Aux PowerAux Power+/+/-- 24 Vdc24 Vdc
(Displacement probes)(Displacement probes)
Unit Input Power Unit Input Power 24 Vdc 24 Vdc
OROR110 / 220 VAC110 / 220 VAC
16 Tach Channels16 Tach Channels1x Peak and Phase-- PulsePulse--type speed inputstype speed inputs-- Frequency dividerFrequency divider-- Adaptive tach featureAdaptive tach feature
-- autoauto--locks on speedlocks on speed
16 Digital I/O16 Digital I/O-- Input and outputsInput and outputs-- OPTOOPTOTM TM relay modulesrelay modules
Processor / Processor / CommComm-- Ethernet HUB and NICEthernet HUB and NIC-- 1 Predictive Processor1 Predictive Processor-- 1 Processor feeding live updates1 Processor feeding live updates-- Up to 32 Mb memoryUp to 32 Mb memory-- New Local DisplayNew Local Display
CSI 4500 Machinery Health MonitorTechnical DetailsCSI 4500 Machinery Health MonitorCSI 4500 Machinery Health MonitorTechnical DetailsTechnical Details
Uses all three levels of vibration analysis– Gross Scan (Overall)– Parameter banding,
trending and alarming– Spectrum and waveform
You determine the conditions under which data is collected and how often it is stored.
CSI 4500 Machinery Health MonitorTechnical DetailsCSI 4500 Machinery Health MonitorCSI 4500 Machinery Health MonitorTechnical DetailsTechnical Details
12, 16, and 32 analog input channels available
CSI 4500 Machinery Health MonitorTechnical DetailsCSI 4500 Machinery Health MonitorCSI 4500 Machinery Health MonitorTechnical DetailsTechnical Details
Boiler Feed Water PumpsOption 1
8 Proximity Probes and one tachometer per
pump
Option 25 Accelerometers
and one tachometer per
pump
Cooling Water Pumps5 Accelerometers and one
Tachometer per pump
JBOX JBOX
JBOX JBOX JBOX
Dedicated Ethernet (or wireless) provided by customer
MHM Server
Common Server for MHM Online and LAN
Software
Plant Control System
Plant Network
Control RoomOnline Watch
EngineeringOnline Watch
PDM GroupAMS Machinery
Manager
MaintenanceAMS Machinery
Manager
Digital I/O to DCS
4500 Connectivity4500 Connectivity4500 ConnectivityAMSAMS
Asset PortalAsset Portal
AMS AMS DeviceDeviceManagerManager
AMS AMS MachineryMachinery
ManagerManager
CSI 4500CSI 4500Machinery HealthMachinery Health
MonitorMonitor
Critical Machinery Critical Machinery
Ethernet
OperationsOperations MaintenanceMaintenance
XML*Other Control SystemsOther Control Systems
CSI 4500 Machinery Health MonitorTechnical DetailsCSI 4500 Machinery Health MonitorCSI 4500 Machinery Health MonitorTechnical DetailsTechnical Details
Predicate based data collection
Digital I/OSpeed
Analog Input
Predicate Based Data CollectionPredicate Based Data CollectionPredicate Based Data CollectionOverall Vibration
0
0.2
0.4
0.6
0.8
1
1.2
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
Time
Ampl
itude
Predicate Based Data CollectionPredicate Based Data CollectionPredicate Based Data CollectionOverall Vibration w/ RPM
0
500
1000
1500
2000
2500
3000
3500
4000
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
Time
RPM
0
0.2
0.4
0.6
0.8
1
1.2
RPMOverall
Predicate Based Data CollectionPredicate Based Data CollectionPredicate Based Data CollectionOverall Value by Speed
0
0.2
0.4
0.6
0.8
1
1.2
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
Time
Ampl
itude
High speedLow Speed
High Speed Alarm
Low Speed Alarm
Failure CurveFailure CurveFailure CurvePr
obab
ility
of F
ailu
re
Time
Infant Mortality Expected Life End of Life
Failure
Fault Progression
Predictive System Protection System
Machinery Applications in a Typical PlantMachinery Applications Machinery Applications in a Typical Plantin a Typical Plant
Online Monitoring
Portable
~125 Machines
~625 Machines
~500 Machines
~500 Machines
Total # Machines 2,500Typical Industrial Process Plant
5%5%CriticalCritical
25%25%EssentialEssential
30%30%ImportantImportant
20%20%SecondarySecondary
20%20%NonNon--EssentialEssential
TurbinesGenerators
Compressors
MotorsPumps
FansGears
Run to Fail
Portable
Automated Data CollectionPeriodic Data Collection
CSI 4500 Monitor
CSI 9210Transmitter
Loss of machine meansLoss of machine means> 40% lost plant capacity> 40% lost plant capacity
CSI 2130Analyzer
~750 Machines
Installed Systems & ApplicationsSummary of Customers by IndustryInstalled Systems & ApplicationsInstalled Systems & ApplicationsSummary of Customers by IndustrySummary of Customers by Industry
Questions??Questions??