53512817 vibration monitoring

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??