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2008-03-21 ©SKF Slide 1SKF Mining, Mineral Processing & Cement
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2008-03-21 ©SKF Slide 2SKF Mining, Mineral Processing & Cement
SKF Copperhead fault detection
Presented by SKF 1 Industrial Team
2008
SKF Mining, Mineral Processing and Cement
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2008-03-21 ©SKF Slide 3SKF Mining, Mineral Processing & Cement
Services platform
Training
Mechanical
RCFA
Engineering Consultancy
PdM
PRM
IMS Asset Management Services
Services
Asset Efficiency Optimization
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2008-03-21 ©SKF Slide 4SKF Mining, Mineral Processing & Cement
SKF Copperhead fault detection
• Crushers• Conveyors• Grinding mills• Vertical grinding mills• Fans• Vibrating screens• Hoists• Pumps, motors, gears
Machinery fault detection
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2008-03-21 ©SKF Slide 5SKF Mining, Mineral Processing & Cement
CMPT sensors(vibration and temperature)- Rugged, low profile design- High shock resistance- Permanent mounted in machine
CMPT CTUVibration and temperature transmitter
(Enveloping, Acceleration and Velocity)Early detection of vibration faults
Two 4 to 20 mA proportional signal
CMPT DCL display / alarm moduleDigital display and alarm for vibration
and temperature (°C)Each system provides optional- Stand alone ALARM function- Visual LED lamp for ALARM- Internal relay contacts (48 V DC / 0.5 Amp)
Prevent unplanned downtime, reduce maintenanceand repair costs, improve productivity, improve safety
Basic components
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2008-03-21 ©SKF Slide 6SKF Mining, Mineral Processing & Cement
New family of SKF Copperhead sensors
CMPT family of sensors
Vibration Temperature
CMPT 2310 100 mV/g no
CMPT 2310T 100 mV/g 10 mV/°C
CMPT 2323 230 mV/g no
CMPT 2323T 230 mV/g 10 mV/°C
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2008-03-21 ©SKF Slide 7SKF Mining, Mineral Processing & Cement
CMPT CTU transmitter
Vibration and temperature transmitter
• Three types of vibration analysis- SKF Acceleration Enveloping(gE3)- Acceleration (g)- Velocity (mm/s)
• Features for monitoring low speed (n < 40 r/min)
• Process signals out – vibration and temperature- 4 to 20 mA and 0 to 10 V DC
• Front panel user configurable
• Front panel BNC- buffered vibration and temperature
• 24 V DC, DIN rail mounting
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2008-03-21 ©SKF Slide 8SKF Mining, Mineral Processing & Cement
SKF Copperhead C series fault detection kit
Benefits•Connectable to PLC automation systems
•Integrates vibration and temperature
•Lowest possible costs
SKF CPHD 1C kit
(1) CMPT 2310T sensor(1) CMPT CTU transmitter
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2008-03-21 ©SKF Slide 9SKF Mining, Mineral Processing & Cement
CMPT DCL display / alarm module
• Monitors CMPT CTU, thermocouples and
Resistive Temperature Detectors (RTD)
• 7 mm digital display
- Vibration (gE, g, mm/s, inch/s)
- Temperature (°C, °F)
• Programmable alarm functions
- High, Low, High-Low
- Event lamp (red)
- Relay contacts (48 V DC/AC, 0.5 Amp maximum)
- Latching / Non-latching
• 4 to 20 mA output signal
• 24 V DC, DIN rail mounting
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2008-03-21 ©SKF Slide 10SKF Mining, Mineral Processing & Cement
Enclosure for Copperhead kits
CPHD EC style enclosure
Painted steel with window
IP66 / NEMA 4
Optional stainless steel available
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2008-03-21 ©SKF Slide 11SKF Mining, Mineral Processing & Cement
options
Periodic MonitoringCPHD 1B , CPHD 2B
MicrologMarlin PRO
Continuous MonitoringCPHD 2EC, CPHD 3ECM, …
PLC / DCS
Microlog
4 to 20 mA vibration4 to 20 mA temperature
CTU Unit
SKF Copperhead fault detection kits
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2008-03-21 ©SKF Slide 12SKF Mining, Mineral Processing & Cement
SKF Copperhead for vibrating screens
Fault detection• Monitors the whole machine• Extends screen life
CMPT2310T sensor(vibration and temperature)1 x each bearing2 x each gearbox
BNC UnitFor periodic monitoring
CTU Unitfor continuous monitoring
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2008-03-21 ©SKF Slide 13SKF Mining, Mineral Processing & Cement
Gear faults
Lubrication problems
Overloading
Bottoming out
Bearing faults
Loose screen mesh
Loose components
Screen not running / broken belt if connected to PLC
Fault detection for vibrating screens
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2008-03-21 ©SKF Slide 14SKF Mining, Mineral Processing & Cement
For all types and styles of crushersRolling and journal bearings
SKF Copperhead for crushers
Monitor machinery faults to
extend machine performance
• Mechanical looseness
• Rotor unbalance
• Gear faults
• Bearing faults
• High temperature
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2008-03-21 ©SKF Slide 15SKF Mining, Mineral Processing & Cement
SKF Copperhead fault detection for crushers
IDLE/CRUSH sensor mounted on crusher body away from shaft.
Optional Crusher Module (CM) for stand-alone monitoring
SKF Copperhead monitors for faults during IDLE mode
0.00
20.00
40.00
60.00
80.00
100.00
Time
Vibr
atio
n gE
3 (
% )
30 g
E3 fu
ll sc
ale
Vibration from platehitting crusherCRUSHINGIDLE
Pasminco Mine - Symons crusherSKF acceleration enveloping
4 June 2002 18:17:32 to 18:33:16
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2008-03-21 ©SKF Slide 16SKF Mining, Mineral Processing & Cement
Example - Jaw Crushers CPHD 4EC
Monitor machinery faults
and extend machine performance
• Mechanical looseness (toggles, wear parts)
• Bearing faults
• High temperature
Frame bearing housings
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2008-03-21 ©SKF Slide 17SKF Mining, Mineral Processing & Cement
SKF Copperhead fault detection for cone crusher
Gearbox, motor
CMPT2310T
Vibration and temperature monitoringCMPT2310T(vibration and temperature)1 x gearbox1 x motor
Fault detection for pinion drives • Mechanical looseness• Gear faults• Bearing faults• High temperature
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2008-03-21 ©SKF Slide 18SKF Mining, Mineral Processing & Cement
SKF Copperhead fault detection for impact crushers
Main bearings, gearbox, motor
CMPT2310T
CPHD 1C for each bearing
Fault detection• Mechanical looseness• Gear faults• Bearing faults• High temperature
CPHD 1C/10 kit to monitor overall
crusher vibrations
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2008-03-21 ©SKF Slide 19SKF Mining, Mineral Processing & Cement
SKF Copperhead fault detection for roll crusher
Vibration and temperature monitoringCMPT2323T sensor (n<40rpm)(vibration and temperature)1 x each bearing1 or 2 x each gearbox1 or 2 x each motor
Twin and Quad roll
Fault detection for roll crusher • Mechanical looseness• Gear faults• Bearing faults• High temperature
CMPT2323T
Periodic or continuous monitoring
Crusher module for Idle/Crushing
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2008-03-21 ©SKF Slide 20SKF Mining, Mineral Processing & Cement
SKF Copperhead for pinion drives
Pinions, gearbox, motorVibration and temperature monitoringCMPT2310T sensors2 x pinions1 or 2 x gearbox1 or 2 x motor (rolling and journal bearings)
Fault detection for pinions• Mechanical looseness
• Gear faults
• Bearing faults
• High temperature
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2008-03-21 ©SKF Slide 21SKF Mining, Mineral Processing & Cement
SKF Copperhead fault detection for trunnions
Trunnion
CMPT2323T
CMPT CTU transmitter set for low speedCMPT2323T - low speed sensor
Fault detection for grinding mills • Mechanical looseness• Gear faults• Bearing faults• High temperature
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2008-03-21 ©SKF Slide 22SKF Mining, Mineral Processing & Cement
SKF Copperhead for vertical mills
1 sensor per roller
2 sensors on gearbox- pinion and frame
Motor
1 or 2 sensors
Fault detection• Mechanical looseness• Gear faults (except some inside gears)• Bearing faults• High temperature
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2008-03-21 ©SKF Slide 23SKF Mining, Mineral Processing & Cement
SKF Copperhead fault detection for rollers
Oil inlet and outlet
Sensor (CMPT 2323)(one sensor per roller)
• Bearing faults• Mechanical looseness
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2008-03-21 ©SKF Slide 24SKF Mining, Mineral Processing & Cement
SKF Copperhead for bulk conveyors
Pulleys, gearboxes & motors
CMPT 2310T sensor(vibration and temperature)One sensor per housing
Fault detection
• Mechanical looseness
• Bearing faults
• High temperature
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2008-03-21 ©SKF Slide 25SKF Mining, Mineral Processing & Cement
Y bearings, ConCentra, Unit Roller, Pop-Release
SNL, SAF, SOFN
PD
SKF Copperhead for fans
CMPT2310T sensor(vibration and temperature)One sensor per housing
Fault detection
• Unbalance
• Mechanical looseness
• Bearing faults
• High temperature
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2008-03-21 ©SKF Slide 26SKF Mining, Mineral Processing & Cement
SKF Copperhead for mine hoists
Fault detection for bearings, gearboxes, drives
• Mechanical looseness
• Gear faults
• Bearing faults
• High temperature
CMPT2310T
Vibration and temperature monitoringCMPT2310T(vibration and temperature)1 x each bearing1 x each gearbox1 x each motor
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2008-03-21 ©SKF Slide 27SKF Mining, Mineral Processing & Cement
Detect pump cavitation
Mount CMPT 2310T sensor (radially) on pump frame.
See CMPT CTU to Acceleration Enveloping
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2008-03-21 ©SKF Slide 28SKF Mining, Mineral Processing & Cement
SKF Copperhead fault detection
Features
• Rugged vibration/ temperature sensor
• Permanent mounted on machine
• Acceleration Enveloping, Acceleration,
Velocity analysis
• Easy to use CTU system, PLC capable
• Stand alone system or integrated
• Pre-engineered
Benefits
• Long, reliable service
• Repeatable signals/improved safety
• Early fault detection
• Little training necessary, functional system
• Can meet individual requirements
• Easy to order
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2008-03-21 ©SKF Slide 29SKF Mining, Mineral Processing & Cement
SKF resources
www.aptitudexchange.com
SKF @ptitude Exchange is SKF's knowledge source for asset maintenance and reliability expertise. White papers, interactive services, tutorials, etc., are now at your fingertips.Register for FREE, and learn about subscriptionoptions.
See www.skf.com for additional solutions
DSP is SKF’s tool to document the value
and Return on Investment (ROI) for its solution.
SKF Documented Solutions program (DSP)
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2008-03-21 ©SKF Slide 30SKF Mining, Mineral Processing & Cement
• Improve productivity and profitability
• Improve health and safety
• Improve the environment
SKF Copperhead fault detection
® SKF and @ptitude are registered trademarks of the SKF Group
The contents of this publication are the copyright of the publisher and may not be reproduced (even extracts) unless prior writtenpermission is granted.
Every care has been taken to ensure the accuracy of the information contained in this publication but no liability can be accepted for any loss or damage whether direct, indirect or consequential arising out of use of the information contained herein.
© 2008 SKF Group Version 1/2/2008
For more information, contact your SKF Authorized Distributor,
your SKF Representative, or e-mail us at [email protected]
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2008-03-21 ©SKF Slide 31SKF Mining, Mineral Processing & Cement
SKF has solutions for the mining,
mineral processing, &
cement industry
SKF mining, mineral processing & cement
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2008-03-21 ©SKF Slide 32SKF Mining, Mineral Processing & Cement