online_failure detection

Early detection of machinery failures using online

Condition Monitoring Systems (CMS)

PRUFTECHNIK Middle East FZE (Dubai) / Robert Schmaus / 28-04-2013

27/04/2013 PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 2


Agenda

- Content

►Brief company profile

►Introduction to CM

►A typical plant

►Machine health monitoring

►CM technologies

►Level 1 & Level 2 strategy

►The right measurement tools

►Is online monitoring needed?

►Case studies

►Examples of online CMS installations

►Summary

COMPANY PROFILE

PRUFTECHNIK


PRÜFTECHNIK Group facts

► Location of headquarter: Ismaning (Munich), Germany

► Divisions:

● PRÜFTECHNIK Condition Monitoring GmbH

● PRÜFTECHNIK Alignment Systems GmbH

● PRÜFTECHNIK NDT GmbH (Nondestructive Testing)

► Founded in 1972 by Dieter Busch

► PRÜFTECHNIK Group CEO: Dr. Sebastian Busch

► Activities:

● Research & Development

● Production

● Sales and service of electronic and electrical instruments,

especially measurement and control systems.

► Patents & Trademarks: 300 patents & 150 trademarks worldwide

► Quality Management: ISO 9001 since 1994

► Staff: approximately 550 employees

► Sales turnover 2012: approx. 70 millions EURO

► Sales Channel Network in over 70 countries

PRÜFTECHNIK general HQs in Germany

Dieter Busch Dr. Sebastian Busch


Worldwide sales channel network

PRÜFTECHNIK maintains an international sales network

covering more than 70 countries


PRÜFTECHNIK – a reliable long-term partner

Since the foundation of PRÜFTECHNIK

in 1972, the company has maintained a

reasonable growth of sales turnover,

company organization and employees.

PRÜFTECHNIK invests over 15% of its

annual sales turnover in R&D and every

year in order to ensure product

enhancements and development of new

products.

Today more than 80% of the turnover is

achieved with products which are no

more than 4 years old.

A substantial role in this is played by

the development department which still

makes up 25% (a quarter!) of the

workforce.

The high export quota of approx. 80% is

a distinguishing feature of technically

qualified products


Main product launches for Condition Monitoring

1980 VIBROSPECT®

1980 VIBROCORD® 1

1989 SYSTEM 2

1992 X-Tector

1993 VIBROTIP®

1995 VIBCODE®

1996 VIBRONET®

1997 VIBREX®

1998 VIBROCORD® 2

1999 VIBRONET® Signalmaster

2000 VIBSCANNER®

2003 smartSCANNER®

2004 VIBROWEB®

2004 VIBXPERT®

2005 VIBROWEB® XP

2005 VIBNODE®

2009 WearScanner®

2010 VIBXPERT® II

2011 VIBCONNECT®

2012 VIBGUARD®

VIBROSPECT® VIBROCORD® 1 SYSTEM 2®

VIBROCORD® 2 VIBSCANNER® smartSCANNER®

VIBXpert® II VIBXpert® EX VIBXpert®


http://www.pruftechnik.ca/javasc

PRUFTECHNIK awards

Year Product Award

2010 VIBXPERT® II Product of the Year 2010 – Winner (Inżynieria i Utrzymanie Ruchu)

2010 VIBXPERT® II Product of the Year 2010 – Finalist (Plant Engineering Magazine)

2010 VIBXPERT® II TOP 2 in 2010 IMPOvation Awards

2010 VIBXPERT® II Honorable Mention in the 2011 / AHR Expo Innovation Awards Competition

2010 VIBXPERT® II Breakthrough Product of 2010 (Processing Magazine)

2010 VIBXPERT® II Product Innovation of the Year – 4th place (Pumps & Systems)

2010 PARALIGN® Industriepreis 2010 (Huber Verlag für Neue Medien)

2009 INCLINEO® Breakthrough Product of 2009 (Processing Magazine)

2009 INCLINEO® Product of the Year 2009 – Finalist (Plant Engineering Magazine)

2009 ROTALIGN® Ultra IMPOvation product technology award (IMPO Magazine)

2008 VIBXPERT® EX Product of the Year – Finalist (Plant Engineering Magazine)

2008 OPTALIGN® smart Designpreis 2008 Nominee (Designpreis der Bundesrepublik Deutschland)

2007 PARALIGN® Technology of the Year Award (AIMCAL)

2007 PARALIGN® Matteucci Award Winner (AIMCAL)

2007 OPTALIGN® smart Product of the Year – Gold Award (Plant Engineering Magazine)

2007 OPTALIGN® smart red dot design award (Design Zentrum Nordrhein Westfalen)

2007 OPTALIGN® smart Product of the Year – Finalist (Plant Engineering Magazine)

2006 ROTALIGN® Ultra Product of the Year – Silver Award (Plant Engineering Magazine)

2005 PARALIGN® Palme d’Or des trophées de l’innovation 2005 (ATIP)

2005 ROTALIGN® Ultra Best of NED' Problem-Solver (New Equipment Digest (NED))

2005 ROTALIGN® Ultra Breakthrough Product (Processing Magazine)

2003 smartSCANNER® Product of the Year – Finalist Plant Engineering Magazine)

2003 smartSCANNER® Breakthrough Product (Processing Magazine)

2002 VIBSCANNER® Product Of the Year Award (Fluid Handling Systems Magazine)

2001 VIBSCANNER® Product of the Year – Gold Award Plant Engineering Magazine)

2000 VIBSCANNER® Roter Punkt für Hohe Designqualität Design Zentrum Nordrhein Westfalen

1997 OPTALIGN® PLUS Product of the Year – Silver Award (Plant Engineering Magazine)

1996 OPTALIGN® PLUS IF Product Design Award (Industrie Forum Design Hannover)

1993 VIBROTIP® Roter Punkt für Hohe Designqualität (Design Zentrum Nordrhein Westfalen)

1992 TURBALIGN® Product of the Year – Bronze Award (Plant Engineering Magazine)


//pt-agf1/xchg/Allgemein/IntraNet/entry/images/Intros/intro_intranet_034L.jpg

http://www.pruftechnik.ca/javasc

04/02/2013 PRUFTECHNIK Middle East FZE (Dubai) - Robert Schmaus 11

Some of our target markets

Oil & Gas Off Shore Power

Wind

Marine

Chemical Paper / Films

Sugar

Textile Cement

Mining

Steel

Water

Services Automotive

Some worldwide references


Cooling Towers

FEWA - United Arab Emirates

Saudi Arabia

Bahrain Petroleum Company

Qatar Shipping Co.

Saudi Arabia

http://www.kimberly-clark.com/

http://www.fxc.com/


Introduction


Predictive Maintenance helps to

► Increase machine reliability

► Ensure machine availability

► Secure productivity

► Decrease maintenance costs

► ... And finally helps to optimize profits

Increase profitability in your plant

Years

Productivity

Costs

PROFIT


Time

Why CM?

Starting

point of a

failure

Evolution

into

vibration Wear

particles in

oil

Increased

noise

Heat

development

Functional

failure

CM shows the optimal time for intervention on machines


Example of a successful CM pilot project

CM Vibration Analysis concept was started in 1990. The concept was realized

in 1991 and covered approximately 250 pumps.

Usually 100 maintenance stops were required due to failures on pumps

Main problems were the bearings

Anual repair costs: 160,000 USD (without production losses, etc)

After implementation of a CM strategy the number of repairs per year

decreased

Nu

mb

er

of

rep

air

s


A typical plant


IMAGINE THIS IS YOUR PLANT

So... how are your machines doing?

Conveyors

Kiln Cooler Prehomogenization Raw material storage Roller Mill Packing Cement silo

Quarry Crusher Preheater Clicker silo Cement mills Raw meal homogenization

1 2

4

3

5

7

8

9

10

11

12

13

14

You know how your production is doing. Fine.

But what about the health of each machine involved in production?

6

Simplified example of a cement plant


So... how are your machines doing?

Conveyors

Kiln Cooler Prehomogenization Raw material storage Roller Mill Packing Cement silo

Quarry Crusher Preheater Clicker silo Cement mills Raw meal homogenization

1 2

4

3

5

7

8

9

10

11

12

13

14

Condition monitoring allows to detect problematic machines before a damage unexpectedly

interrupts the production process

Condition monitoring tools identify machines at an early deterioration stage and classifies them

into different categories reflecting severity of health

GREEN = long term operation is OK / YELLOW = restricted operation allowed / RED = machine did

run into alarm status; must be stopped immediately

6

DETECT PROBLEMATIC

MACHINES


Machine health

monitoring


Breathing frequency

Condition Monitoring = Health Monitoring

Breathing trend

Oxygen trend

Vein pressure trend

Arterial blood pressure trend

Electro cardiogram trend

Oxygen in blood

Values of

artificial

respiration

Central vein pressure

Blood pressure

Alarms Heart rate

- Applied to human being health monitoring

► Measuring parameters such as blood pressure, temperature, etc

► Trending values when required

► Analyzing changes over time

Control panel

TRENDS

VALUES


Condition Monitoring?

- Monitoring machinery health

► DEFINITION: Condition monitoring is the process of monitoring parameter of

machinery health or machinery condition, such that a significant change is

indicative of a developing failure.

► Rotating machinery reveales its condition via parameters such as:

● Vibration

● Temperature

● Oil samples

● Sound

● Motor current

● Etc

► Such machine parameters are measured with the aid of diverse technologies

Condition Monitoring technologies


Infrared thermography

19%

Oil analysis

14%

Other

9%

Ultrasound

7%

Motor current

analysis

3%

Vibration

analysis

48%

Process parameters ≠ condition monitoring parameters


Level 1 and Level 2

strategy


Level 1 & Level 2

Level 1

Where is the problem?

Detection of machines with problems

Level 2

What is the problem?

Analysis: finding the root cause of

problems

Example:

Level 1 measurements detect changes in the machine

condition

Measurement value trends increased over a time period

Changes in machinery health occur: vibration levels are

higher, machine condition is deteriorated

Example:

Analysis of FFT spectra and envelope spectra

Find source of problems e.g. unbalance,

misalignment

Diagnose and correct problem, e.g. balance rotor,

align machine shaft, etc


Level 1 & Level 2

Level 1

Detection

Level 2

Analysis

Example:

Performing vibration measurements periodically allows

to detect a machine with poor condition

Vibration levels increased compared to previous

measurements

Machine condition is clearly deteriorated – but why?

Level 2

Overall value measurement trend

Example:

Analysis of FFT spectra and envelope spectra

Find source of problems e.g. unbalance,

misalignment

Diagnose and correct problem, e.g. balance,

align machine shaft

Vibration

value

time

Prewarning level

Alarm level

Warning level


Typical Reliability based Maintenance work flow

Define and perform measurements

of Level 1 & 2, depending on the

machine and the typical failures

expected to be detected (fast failure

evolution / online measurements /

Offline measurements / etc.)

Detection: trending of collected

measurement data of overall values.

Intelligent alarming is required here.

(Level 1)

Analysis: when relevant changes

occur to the values in the trends,

analyze Level 2 measurements

Diagnostic: based on the

interpretation of Level 2

measurements, formulate a

diagnostic and action

Correction: select the appropriate

correction method to correct the

failure and eliminate the failure root

cause*

1) DEFINITION

2) DETECTION

3) ANALYSIS

4) DIAGNOSTIC

5) CORRECTION

Example gearbox: RPM, bearing

types, number of teeth, number of

stages, etc.

Example: elevated overall vibration

value on motor drive side

Analyze the increased vibration peaks

and the characteristic frequencies : 1x,

2x, gear mesh = RPM x number of

teeth, etc.

Diagnose and describe the failure as per

Level 2 measurements – formulate the

root cause of failures

Misalignment align with laser alignment

Imbalance perform dynamic filed balancing

*After the correction phase, it is necessary to recheck the machine condition

again, to ensure that there is a real vibrational enhancement of the machine


The right

measurement tools


Tools used for vibration analysis

- Condition monitoring / vibration analysis

► Vibration data collectors can be:

● Portable data collector and analyzer

■ Mobile instrument and sensors

■ Fixed installed sensors connected to junction boxes

● Online Condition Monitoring Systems (online CMS)

● Machine protection

► Powerful software platform:

● Storage of collected measurement data

● Analysis and diagnosis of problems

● Reporting capabilities

● Interface to e.g. CMMS (SAP, Maximo) etc


Offline measurements


Portable data collector (offline) 1

Manual data collection with

portable instrument on a

large number of machines

Machine (pump)

Measurement

sensors attached to

machines via

magnetic bases

Collected data is

stored on a

software platform

(database),

analyzed and

printed into reports

VIBXpert® II instrument


Portable data collector (offline) 2

- Junction box (“SwitchBox”)

► Permanent sensors mounted on machines are connected to junction boxes

► Data is still manually collected but from a safe location

► Ideal for machines in hazardous or restricted areas

► Faster data collection than with mobile sensor and data collector

-Multiplexer support

(Automatic Switchbox)…

-just a step before

implementation of online CMS



► Concept of a standard (manual)

switchbox:

● safe, reproducible and reliable

measurement of

● remote or hard to reach

locations

► VIBXPERT® II multiplexer support:

● The above features PLUS

● Automatically switching through

the channels – up to 54 per line

● "One click measurements"

→ click once – have a coffee

► A time saving feature for safe,

reliable and fast measurements

► First step towards implementation of

online systems (CMS)

…

Intelligent MUX measurements



► The feature can also be used in

intrinsically safe environment

► All that is needed is the ATEX

version of the multiplexers,

sensors, cables…

► … and a limiting device.

► The instrument connects then in

the non-EX area and enters the

ATEX area via the limiting device

VIB 3.550

Limiting

device

Multiplexor VIB 8.306

EX* with according

sensor cards

(VIB 8.314EX for ATEX

vibration sensors) Vibration sensors VIB 6.122DEX

Intelligent MUX measurements



Online Condition

Monitoring systems

(CMS)


Online data collection

Sensors are permanently mounted on critical machines

Online CMS automatically collects data and handles alarms

Monitoring ‘around the clock’

Simplified example of a cement plant

Database

Sensors

& Online

CMS

LAN /

Ethernet Internet

RPM, temperature, process

parameter,etc

Sample main functions of an online CMS

VIBNODE®

online CMS

Switch off

Communication

with DCS / SCADA

Via Filedbus

Measurements, alarms, etc.

MACHINE PROTECTION PREDICTIVE MAINTENANCE

PLC

OMNITREND®

Software Platform

LAN / Ethernet

SENSORS

CABLES


CMS interfaces and functions (examples)

LAN/Ethernet

12 analog inputs

(e.g. accelerometers) 2 RPM

signals

2 digital inputs

(“trigger” for turn on/ turn off the

machine) TTL 5V…+30V

Control room

Visualization of the

measurement results

Example: Profibus, Modbus

Control panel

Visualisation of the

measurement results

e.g. stop of machine

Optional (VIB 7.112)

Two outputs 4-20mA

3 digital outputs

+30V / +0.1A

e.g. Acustic alarms

e.g. visual alarms

e.g. For stopping the machine

(*it is not a protection system)

RS232/1 serial communication

Wireless Transfer of

measurement data and

access toCMS

Notebook

RS232/2 serial communication

(System Fieldbus: Modbus, Profibus)

SPC/PLC


Sample online CMS architecture

Measurements

Processing

Storage

Communication

VIBNODE®

VIB 7.150-SET-SO

Analog inputs 1 to 12, configurable as standard per jumper to

also ICP (voltage) sensors, +/- 5V or +/- 20 mA.

Digital inputs:

Analog inputs:

Power supply.:

A_1 -BA11101 analog input 1





A_6 -Bn11106 analog input 6






A_12 -Bn11112 analog input 12

N_1 -BN11201 Puls/RPM 1

N_2 -BN11202 Puls/RPM 2

24V 230VAC / 24V DC 24 V-Switch 24VSW+

-BD11205 System OK (FET) SYS-FET

-BD11206 Digital output 1 OUT_1



Digital outputs:

Ethernet TCP/IP

RJ45, 10MBit/s Ethernet

Communication:

Interface relay

Power supply

VIB 5.964-0,8

(optional)

Phone connection analog /

GPRS (optional) RS 232/1

Fieldbus Profibus-DP

(optional) or other ‘protocol

converter’. Other

converters available upon

request.

RS 232/2

Fieldbus-Module

VIB 5.920-PDP

(optional)

Modem

VIB 5.93x-xxx

(optional)

Cabinet IP65 (Larger cabinet dimensions: approximately 300 x 200 x 130 mm)

IN_1 -BD11203 Digital input 1

IN_2 -BD11204 Digital input 2

Interface relay

Interface relay

Interface relay


OMNITREND® software platform

Representation of machines,

including measurement

points and measurement

tasks, with individual

settings for each point and

tasks

Visual detection of alarms

highlighted with colored flags :

red (alarm), yellow (warning), etc.

Problem analysis, diagnostic

and identification of the root

cause of problems

Setting of narrow-band

alarms (etc) for accurate

fault monitoring and

diagnostic trends allow

predictive view of health of

machines.

OMNITREND® is used also

to configure all tasks etc. in

the online CMS.


3-D Spectra, waterfall diagram


CMS in action in water plant in Germany

VIBNODE® CMS interior (example)

VIBNODE® Online CMS (large cabinet)

Vibration sensors*

*Location and number of sensor varies depending on machine characteristics


SENSOR INFORMATION

A SHORT OVERVIEW*

*) for additional information please refer to existing documentation such as but not limited to brochures, catalogs, manual, technical notes, etc.



TANDEM-Piezo®, the 2-in-1 sensor

Coverage of standard

vibration frequencies

(range e.g. 1Hz – 20kHz))

1) VIBRATION 2)

BEARING

CONDITION

PUMP

CAVITATION

Coverage of higher

frequencies

(sensor resonance @ 36kHz)

ATEX

option

Options for mounting sensors on machines

Option 1:

Type VIB 6.1xx sensor with

90° base screwed directly

onto machine

Option 2:


90° base screwed into

adapter which is bonded

onto machine

Option 3:


flat base bonded directly

onto machine

Screw-in sensor

Bonded adapter

Bonded sensor Screw-in sensor


Examples of bonded adapters

ICP type

CLD type CLD type


Typical mounting of CLD vibration sensor

Clamp VIB 6.720

Clamp VIB 6.721

Protective cap VIB 6.700

Sensor VIB 6.122 type

Dust cap sleeve VIB 6.722

The VIB 6.122 accelerometer

sensors can be

1) screwed into drilled/tapped

holes – or – 2) screwed on

adapters as this one; adapter only

is bonded to the machine.

Or, 3) additionally special

“bonded sensors “(mounted with

special glue/Loctite) can be

mounted without drilling the

machine e.g. VIB 6.102R sensors.

Different cable options for EX

or non-EX areas


Accelerometer sensor VIB 6.122R / VIB 6.122 DEX* CLD type

Dimensions

Mounting instructions

*Instead of threaded sensors, bonded sensors available on request!



When do I need online

CMS?


Offline measurements cannot detect intermittent problems

But I already measured

this machine and did not

find any irregularities...!!!*

*Hmm... How to find problems that do no show up while performing offline measurements?


100% of all machines in

the plant A

Why online? “ABC Analysis”

Do I need to monitor all machines with online CMS?

Less relevant machines, low or none impact on production C

Critical machines (also auxiliary critical machines!) B

Very critical machines for production A

B C


Online

protection

systems

Routine inspections

Why online? The right CM tool C

os

ts –

lo

ss

of

pro

du

cti

on

, e

tc

(*time till failure / time between measurements)

$$$

$$

$

Deterioration Sudden failures

Measurements

with portable data

collectors

Online Condition

Monitoring

months weeks days hours minutes seconds years t*


time

Dete

riora

tion

Machine failure types

standard

Fast deterioration

Very fast deterioration

Warning limit

Alarm limit

Interval time between measurements Online / “real time” (protection)

Online / multiplexed CM

Offline / CM intermittent

portable data collector

Failures with very fast deterioration: internal bearing race and rolling elements in bearings, broken shafts, broken fan blades, etc

Failures with fast deterioration: external bearing race, wear in gear tooth, etc

Failures with standard deterioration: general wear in machines, unbalance and misalignment, etc.

Machine failure

Why online? Evolution of failures…


Justification for online CMS

- Some relevant topics are

► Increasing trend towards online CMS

► Machine is critical to the production process

► Detection of rapid evolution of failure

► Operating with a known problem

► Operating beyond original design

► Savings increase profit of plant

► Quality Control

► Reducing overtime costs

► Reducing equipment downtime

► Any many more...



Online CMS are used in every industry having

rotating machinery working in its process. Especially

the so-called critical machinery that has a strong

impact on productivity is monitored with online CMS.

Online condition monitoring is performed in various

industries, such as but not limited to: cement plants,

mining plants, power generation companies, paper

mills, marine industry, wind turbine farms, oil & gas

sector, etc.

Market trends clearly show an increase of machinery health monitoring using

online CMS.

Worldwide more than 1.5 billion USD are spent for Condition Monitoring

solutions.

Approximately 50% of investments – roughly 750 millions USD – represent

acquisition of vibration monitoring equipment

Around 75% of that portion being online CMS, the remaining 25% represent

portable instruments such as vibration data collectors.

Worldwide online CM vs. portable CM

-Increasing trend towards online CMS



- Machine is critical to the production process:

► Comparing the potential cost of a damaged machine in terms of lost downtime is an

excellent way to justify investments and compute the time frame for ROI.

► For example, a process pump is not expensive; however, its impact on production time

may be around $140,000 per hour for a plant.

► Therefore, the value of only one unplanned failure could justify a $60,000 online system.

► ROI would be achieved by early detection of problems and avoiding only one unplanned

failure.

Pumps in an underground mine in Brazil:

A series of pumps with SIEMENS motors are

monitored with the VIBRONET® Signalmaster

online CMS.

Pumping water out of the mine protects all

machines, ensures an uninterrupted production

and is a must for personnel safety.

Even more critical are those pumps directly

involved in the mining process – such as pumps

working with the SAG mills.



Multiplexor VIB 8.306

cable VIB 90005

VIB 6.122R sensors

Original photo of pump in Brazilian mine

Subsurface mining – pump monitoring



time

Dete

rio

rati

on

Vibration: Warning limit

Vibration: Alarm limit

Fast failure evolution

= Measurements with route-based

portable data collector

Slow failure evolution

No detection! Detection possible.

- Detection of rapid evolution of failure:

► Route-based data collection is sufficient for most machinery, with the average collection

interval of 4 weeks. But, there are some machines where failure evolution can happen

quickly, even within hours. A faulty inner race for example propagates very quickly. Early

detection is critical and 4-week collection intervals are simply not enough to capture the

fault as seen on the graphic.



- Operating beyond original design:

► most processes are running near capacity

► The trend in industry is to increase output capacity by 10-15%.

► This often puts machines just beyond design specifications

► Sometimes, this means running into a resonance speed

► Condition monitoring identifies how close the unit is to ultimate performance



- Operating with a known problem:

► After detection of a problem or fault, the next question is, "How much time do we have

before we must shut down" or "Can we make it to the next scheduled intervention?"

► Trending the fault condition reveals information that is important to estimate the time

before failure.

► Vibration value trends clearly detect variations in the health of the machines as shown in

the graphic.

► Additional analysis reveals the root cause of the problem that can be eradicated.

time

Dete

rio

rati

on

Vibration: Warning limit

Vibration: Alarm limit

Machine can easily run

till next scheduled stop

Machine has an increased

failure probability – stop

immediately

MACHINE 2

MACHINE 1

Scheduled maintenance stop



- Quality control:

► Another feature of online monitoring is fast feedback on product quality.

► For example, on a roll process, chatter between rolls and nips can cause

variations in the thickness of the rolled product, producing a "bar" pattern on

the sheet. This fault is commonly known as barring.

A propagating failure equals to decreased

quality of final product, not only in the paper

industry.



- External specialists can help

► In case required external specialist can access the online CMS

► Integrated email server send out notifications in case of alarms

► External specialist can be a “second opinion”

► Plant can outsource the entire monitoring of critical machines

► External specialist can help if plant just lost its specialist until a new one is recruited

VRM KILN MILLS

ONLINE CMS

MACHINES

ANALYSIS

MAINTENANCE OPERATORS

ETHERNET

EXTERNAL

SPECIALIST SCADA HMI


Do plants go for CM?


Case studies


Garadagh Cement (Holcim) - Azerbaijan

- Accurate online monitoring*

► The online CMS at Garadagh Cement in Azerbaijan performs measurements and saves them on the OMNITREND® software platform that displays graphics in form of measurement value trends, spectra, time wave form plots, etc.

► Trends of measured data from monitored compressors and proper alarm settings enable very quick detection of problematic machines.

► On the right top figure the trend of values recorded with a vibration sensor (picture bottom right) clearly shows an increase of the vibration on an air compressor.

► Once an anomaly is detected on a machine, additional measurement data such as spectra is analyzed to find the root cause of the problem.

► After analysis, a diagnosis is done to define the root cause problem that is then eradicated.

Online CMS data visualization (trend values)

Vibration sensor mounted on air compressor

*Source: ZKG Magazine, Holcim, PRÜFTECHNIK


Garadagh Cement (Holcim) - Azerbaijan

► Garadagh Cement decided to use the

VIBRONET® Signalmaster online CMS from

PRÜFTECHNIK as a modern tool to securely

increase machine reliability to help secure

production availability, but also to reduce the

maintenance costs of monitored machines.

► In this case, the maintenance costs for 9

compressors and for a period of only five

months totaled 51,803 EUR.

► The objective was to reduce these costs to 14

500 € – a reduction of a factor 3.6! But the real

sum required for maintenance costs then only

reached 2,134 EUR – an overall reduction of

maintenance costs by a factor of 24.3!

► In other words: maintenance costs have been

reduced to only 4 %, a great result.

Product uptime ensured with online CMS*

Maintenance cost savings

Reduced costs for unplanned stops

*Source: ZKG Magazine, Holcim, PRÜFTECHNIK


Oil & Gas applications

Monitored machinery

- Drilling Machine (Top drive / DDM (Derrick Drilling Machine))

► Variable RPM

► Low speeds

► Variable loads

► Many transient events can

occur

Without Drilling Machine NO OIL !


Monitored machinery

► Measurement locations


Case Study Drilling Machine

Case study I

► Instrument used: PRUFTECHNIK – Germany

► Software: OMNITREND®

► Machine measured: DDM 650 AC (Derrick Drilling

Machine)

► Measured on site, East Azeri, Azerbaijan BP.

► Operating conditions:

● Zero load / Main shaft speed = 269 /

Intermediate shaft speed = 1093

/ Motor speed = 2300RPM.



- Case study I

► Vibration analysis

● BPFI visible in acceleration time -waveform.

380 400 420 440 460 480 500 520 540 560 580 600 620 640 660 680 700 720 740 760 780 800 820 840 860 880 900 920 940t [ms]

-1,0

-0,8

-0,6

-0,4

-0,2

0,0

0,2

0,4

0,6

0,8

a [g] SW IVEL\ 9 SW IVEL RADIAL\ 1012 VXP Gear t ime > 600 - 1s 04.11.2006 06:50:38

M

(43

6,2

5)

BP

FI

BP

FI

Ha

rmo

nic

#2

0 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 320 340 360 380 400f [Hz]

0,000

0,001

0,002

0,003

0,004

0,005

0,006

0,007

0,008

0,009

0,010

0,011

0,012

0,013

0,014

a op [g] SW IVEL\ 9 SW IVEL RADIAL\ 1011 env _400hz-4000L 04.11.2006 06:50:38

(64

,11

) B

PF

I

BP

FI

Ha

rmo

nic

#2

BP

FI

Ha

rmo

nic

#3

BP

FI

Ha

rmo

nic

#4

BP

FI

Ha

rmo

nic

#5

BP

FI

Ha

rmo

nic

#6

BP

FI

Ha

rmo

nic

#7

BP

FI

Ha

rmo

nic

#8

BP

FI

Ha

rmo

nic

#9

BP

FI

Ha

rmo

nic

#1

0

BP

FI

Ha

rmo

nic

#1

1

BP

FI

Ha

rmo

nic

#1

2

BP

FI

Ha

rmo

nic

#1

3

BP

FI

Ha

rmo

nic

#1

4

BP

FI

Ha

rmo

nic

#1

5

BP

FI

Ha

rmo

nic

#1

6

BP

FI

Ha

rmo

nic

#1

7

BP

FI

Ha

rmo

nic

#1

8

BP

FI

Ha

rmo

nic

#1

9

BP

FI

Ha

rmo

nic

#2

0

BP

FI

Ha

rmo

nic

#2

1

BP

FI

Ha

rmo

nic

#2

2

BP

FI

Ha

rmo

nic

#2

3

BP

FI

Ha

rmo

nic

#2

4

BP

FI

Ha

rmo

nic

#2

5

BP

FI

Ha

rmo

nic

#2

6

BP

FI

Ha

rmo

nic

#2

7

BP

FI

Ha

rmo

nic

#2

8

BP

FI

Ha

rmo

nic

#2

9

BP

FI

Ha

rmo

nic

#3

0

BP

FI

Ha

rmo

nic

#3

1

BP

FI

Ha

rmo

nic

#3

2


380 400 420 440 460 480 500 520 540 560 580 600 620 640 660 680 700 720 740 760 780 800 820 840 860 880 900 920 940t [ms]

-1,0

-0,8

-0,6

-0,4

-0,2

0,0

0,2

0,4

0,6

0,8

a [g] SW IVEL\ 9 SW IVEL RADIAL\ 1012 VXP Gear t ime > 600 - 1s 04.11.2006 06:50:38

M

(43

6,2

5)

BP

FI

BP

FI

Ha

rmo

nic

#2

0 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 320 340 360 380 400f [Hz]

0,000

0,001

0,002

0,003

0,004

0,005

0,006

0,007

0,008

0,009

0,010

0,011

0,012

0,013

0,014

a op [g] SW IVEL\ 9 SW IVEL RADIAL\ 1011 env _400hz-4000L 04.11.2006 06:50:38

(64

,11

) B

PF

I

BP

FI

Ha

rmo

nic

#2

BP

FI

Ha

rmo

nic

#3

BP

FI

Ha

rmo

nic

#4

BP

FI

Ha

rmo

nic

#5

BP

FI

Ha

rmo

nic

#6

BP

FI

Ha

rmo

nic

#7

BP

FI

Ha

rmo

nic

#8

BP

FI

Ha

rmo

nic

#9

BP

FI

Ha

rmo

nic

#1

0

BP

FI

Ha

rmo

nic

#1

1

BP

FI

Ha

rmo

nic

#1

2

BP

FI

Ha

rmo

nic

#1

3

BP

FI

Ha

rmo

nic

#1

4

BP

FI

Ha

rmo

nic

#1

5

BP

FI

Ha

rmo

nic

#1

6

BP

FI

Ha

rmo

nic

#1

7

BP

FI

Ha

rmo

nic

#1

8

BP

FI

Ha

rmo

nic

#1

9

BP

FI

Ha

rmo

nic

#2

0

BP

FI

Ha

rmo

nic

#2

1

BP

FI

Ha

rmo

nic

#2

2

BP

FI

Ha

rmo

nic

#2

3

BP

FI

Ha

rmo

nic

#2

4

BP

FI

Ha

rmo

nic

#2

5

BP

FI

Ha

rmo

nic

#2

6

BP

FI

Ha

rmo

nic

#2

7

BP

FI

Ha

rmo

nic

#2

8

BP

FI

Ha

rmo

nic

#2

9

BP

FI

Ha

rmo

nic

#3

0

BP

FI

Ha

rmo

nic

#3

1

BP

FI

Ha

rmo

nic

#3

2

- Case study I

► Vibration analysis

● BPFI in envelope FFT, with family of sidebands.


► This was reported as a level 3 defect. That means you have some time left before you need to replace the bearing, but needs follow up measurements.

► Decision was made to replace the bearing before they started on next drilling job.



- Case study I

- The Bearing:

► Findings:

● Heavy / sharp marks on the inner

race. Contamination and water.

► Cause:

● Most likely vibration damages

during heavy “yaring”.

● Problems with seals

(water in the oil)



- Vibration Analysis of Drilling Machine

2nd Example:

► Instrument used: PRUFTECHNIK – Germany


► Machine measured: DDM 750 AC 1M (Derrick Drilling Machine)

► Measured in Workshop – Factory Acceptance Test (MAERSK JACKUP 3)


● Zero load / Main shaft speed = 216 / Motor speed = 1762RPM.



- DDM 750 AC 1M

► Needed:

■ High resolution time signals

■ High resolution spectrum measurements

□ More than 100,000 lines of resolution possible also with VIBXPERT®



- Vibration Analysis:

0 50 100 150 200 250 300 350 400 450 500 550 600 650 700 750 800 850 900 950 1000t [ms]

-2,5

-2,0

-1,5

-1,0

-0,5

0,0

0,5

1,0

1,5

2,0

2,5

a [g] DDM 750 AC 1M, (FAT)\ 3 RIGHT PINION UPPER\ 1012 VXP Gear t ime > 600 - 1s 20.12.2007 13:13:18

M

(20

3,4

8)

FT

F

FT

F H

arm

on

ic #

2

FT

F H

arm

on

ic #

3

FT

F H

arm

on

ic #

4

FT

F H

arm

on

ic #

5

FT

F H

arm

on

ic #

6

FT

F H

arm

on

ic #

7

FT

F H

arm

on

ic #

8

FT

F H

arm

on

ic #

9

0 50 100 150 200 250 300 350 400 450 500 550 600 650 700 750 800 850 900 950 1000 1050 1100 1150 1200 1250 1300 1350 1400f [Hz]

0,000

0,005

0,010

0,015

0,020

0,025

0,030

0,035

0,040

0,045

0,050

0,055

0,060

0,065

0,070

0,075

0,080

0,085

a op [g] DDM 750 AC 1M, (FAT)\ 3 RIGHT PINION UPPER\ 1008 env _3200hz-6400L 20.12.2007 13:13:25

(13

,45

) F

TF

FT

F H

arm

on

ic #

2F

TF

Ha

rmo

nic

#3

FT

F H

arm

on

ic #

4F

TF

Ha

rmo

nic

#5

► Vibration analysis of the machine during FAT, detected impacts from the cage (train) in the pinion upper bearing.

► Visible both in acceleration time waveform and envelope FFT.

► Bearing was replaced and new measurements performed.

► See next slide.



► New measurements after bearing was changed:

0 50 100 150 200 250 300 350 400 450 500 550 600 650 700 750 800 850 900 950 1000t [ms]

-2,5

-2,0

-1,5

-1,0

-0,5

0,0

0,5

1,0

1,5

2,0

2,5

a [g] DDM 750 AC 1M, (FAT)\ 3 RIGHT PINION UPPER\ 1012 VXP Gear t ime > 600 - 1s 10.01.2008 12:57:25

M

(20

3,4

8)

FT

F

FT

F H

arm

on

ic #

2

FT

F H

arm

on

ic #

3

FT

F H

arm

on

ic #

4

FT

F H

arm

on

ic #

5

FT

F H

arm

on

ic #

6

FT

F H

arm

on

ic #

7

FT

F H

arm

on

ic #

8

FT

F H

arm

on

ic #

9

0 50 100 150 200 250 300 350 400 450 500 550 600 650 700 750 800 850 900 950 1000 1050 1100 1150 1200 1250 1300 1350 1400f [Hz]

0,000

0,005

0,010

0,015

0,020

0,025

0,030

0,035

0,040

0,045

0,050

0,055

0,060

0,065

0,070

0,075

0,080

0,085

a op [g] DDM 750 AC 1M, (FAT)\ 3 RIGHT PINION UPPER\ 1008 env _3200hz-6400L 10.01.2008 12:57:25

M

20.12.2007

10.01.2008

Blue color is the last

measurement.

The impacts from the

bearing cage

disappeared!



- The bearing:

► Cage: Slight wear on the cage and pockets, corrosion and paint.

► Inner race: grayish wear pattern and indentations

► Conclusion:

■ This is not a bearing you would want in a new machine.


Sheaves (fast line / Line sheaves / Chrown block)

Monitored machinery


Fast line sheave lifts up the drilling

machine

Fast line sheave

Drilling machine

Vibration analysis of fast line sheave


- Instrument used:

► Online Condition Monitoring System VIBRONET® Signalmaster

► PRUFTECHNIK – Germany

- Software:

► OMNITREND®, PRUFTECHNIK

- Machine measured:

► Fast line Sheave

► Measured on site, Eirik Raude, OceanRig.

- Operating conditions:

► The wire that goes thru this sheave is lifting and lowering the topdrive.

► Speed is never constant, and load depends on what's hooked up in the topdrive (can be

difficult for vibration analysis)



20.11.2008 21.11.2008 22.11.2008 23.11.2008 24.11.2008 25.11.2008 26.11.2008 27.11.2008 28.11.2008 29.11.2008 30.11.2008 01.12.2008date

0,05

0,10

0,15

0,20

0,25

0,30

0,35

0,40

0,45

0,50

0,55

0,60

0,65

0,70

0,75

0,80

0,85

0,90

0,95

1,00

a [g] Fast line\ Inner\ 107 Ov erall ac c el. >120

0 50 100 150 200 250 300 350 400 450 500 550 600 650 700 750 800f [Hz]

0,0000

0,0002

0,0004

0,0006

0,0008

0,0010

0,0012

0,0014

0,0016

0,0018

0,0020

0,0022

a op [g] Fast line\ Inner\ 1005 Bearing Env elope 22.11.2008 05:52:38

2

3

4

5

6

7

8

9

10

11

12

D

M

(49,

72)

BP

FO

► Bearing trend/noise is slightly developing

► BPFO Pattern in envelope, but we can not be sure, because exact speed is not known.



► Decision was made to replace the bearing during a rig move.

A similar case in the past caused 7 days downtime.

The bearing:

► Water / contamination.

► Indentations, probably from mounting.

• Conclusion:

► Water in the lubrication caused the raised noise. The indentations on the outer race, caused the BPFO in envelope.




► This is what happened to a

sheave bearing which did not

have vibration monitoring

equipment installed.

-

- Unnecessary

costs $$$

Another damaged sheave bearing:


Mud Pump

► Vibration Analysis of Mud Pump Motor:

► Main bearing is monitored online

■ Varial conditions (load, speed)


OMNITREND®

Software Platform

LA

N / E

thern

et

VIBRONET®

Signalmaster

VIB 3.550 Limiting devices

3 ‘string lines‘

with triaxial cable

VIB 90080

General ATEX architecture

Coaxial cable

VIB 90006 (blue)

Mud Pumps – monitored online

MUX 3

machine

7+8+9

MUX 2

machine

4+5+6

MUX 1

machine

1+2+3

Multiplexor VIB 8.306 EX

MUX 6

machine

16+17+18


Vibration Analysis of Mud Pump Motor:

► Instrument used: online CMS VIBRONET®

Signalmaster / PRUFTECHNIK – Germany


► Machine measured: Mud Pump and Motors

► Measured on site => Eirik Raude, Ocean Rig.


● Motor speed = 619 RPM / 89 Strokes

(approx. 50% load)

The drilling rig "Eirik Raude" (Ocean Rig) seen from

the top of the drilling tower.

Mud Pump

The drilling rig "Eirik Raude" (from Ocean Rig)


27.11.2007 25.12.2007 22.01.2008 19.02.2008 18.03.2008 15.04.2008 13.05.2008 10.06.2008 08.07.2008 05.08.2008 02.09.2008 30.09.2008 28.10.2008 25.11.2008date

0,0

0,5

1,0

1,5

2,0

2,5

3,0

3,5

4,0

4,5

5,0

5,5

a [g] Motor A\ NDE\ 107 Ov erall ac c el. >120

0 50 100 150 200 250 300 350 400 450 500 550 600 650 700 750 800f [Hz]

0,00

0,05

0,10

0,15

0,20

0,25

0,30

0,35

0,40

0,45

0,50

0,55

0,60

0,65

0,70

0,75

0,80

0,85

0,90

a op [g] Motor A\ NDE\ 1005 Bearing Env elope 13.12.2007 00:00:40

2

3

4 5

6

7

8

9

D

M

(37,

02)

BP

FO

Mud Pump

► High bearing noise detected from day one,

after system was installed.

Vibration analysis of a mud pump motor:

► noise came down to normal level after bearing was replaced.

► Detected BPFO in envelope spectra.


Mud Pump

► Current is passing through the

bearing during operation.

The Bearing

► The system has detected the same problem in 5 mud pump motors out of six (!).

► Same problem also detected on draw work motors.

► Next time we detect bearing defects in these motors they will install bearings with ceramic balls, to solve the problem.


Draw works, Winches


Draw works, Winches

► Online Monitoring

■ Variable conditions (load, speed)


Floating Production Units

A floating production unit does not have anchors.

To stay in position it uses thrusters.

For this type of drilling rigs the thrusters has to

be count as “critical machinery“

Thrusters are

keeping the rig in

the right position

on the water

surface Thruster


Thruster Monitoring

Thrusters are keeping the

floating rig in the right position

on the water surface and count to

the critical machinery

Thrusters can be

monitored

continuously with

online CMS


Thrusters – examples of failures


Oil Rig Jack Bates –Top Drive monitoring since 2007 (Australia)

VIBRONET® Signalmaster online CMS


Oil Rig Jack Bates –Top Drive monitoring since 2007 (Australia)

SENSOR 1:

Motor NDE Horizontal

Bearing# 6326 MC4

Variable Speed: 200-1200rpm

SENSOR 2:

Motor DE Horizontal

Bearing# 5588 30C


SENSOR 3:

Gearbox Input Axial (High Speed)

Pinion 24 teeth (mounted directly to Motor Shaft)

Low Speed Spur Gear 40 teeth/23 teeth

High Speed Spur Gear 34 teeth/32 teeth

Spur Gear Lower Bearing = McGill BR-1457 Cylindrical Roller

Bull Gear 114 Teeth


MULTIPLEXER JUNCTION

BOX INSTALLATION

VIBRONET® Signalmaster online CMS


Reference letter: Ocean Rig


References


http://www.akersolutions.com/Internet/

http://www.seadrill.com/

http://www.odfjelldrilling.com/

http://www.kcadeutag.com/index.php

http://www.cosl.no/index.cfm

http://www.cosl.no/index.cfm

Maersk (Denmark)

- Online CMS on FPSO

► Online condition monitoring

in EX environment on a FPSO

vessel using VIBRONET®

Signalmaster online CMS

► Additional sensors will follow

in the near future

► Easily expandable by just

adding:

1. Additional multiplexers

2. Cables

3. Sensors

● …. without the need of

buying a new “online

system”



Oil & Gas: tank farms

In this example

three (3) VIBRONET®

Signalmaster online

CMS units cover a

high number of

decentralized

machines.

The intelligent

string line concept

together with the

field multiplexer

make it an ideal

system for this kind

of ATEX application.

Several plants can

be monitored and

information can be

stored on a central

database for further

analysis and

diagnosis.


PLC

Example: power signal, RPM, temperature,

etc

Example: alarm signals, CMS status, etc.

Oil & Gas: refinery pumps

VIB 8.306 EX

field

multiplexors

Triaxial cable VIB 90080

for string lines

LAN/Ethernet

Distances between last sensor on a string line

and the CMS can be 800m. If the online CMS is

located in the middle of a plant it could cover

a total distance of1600m

string line 3

VIBRONET®

Signalmaster


(one per string line)

string line 1 string line 2


Oil & Gas: fuel pumping station

LAN / Ethernet

Internet access

OMNITREND®

software

VIB 6.122DEX vibration sensors

VIB 6.610EX temperature sensors

Triaxial cable

VIB 90080

Online CMS:

VIBRONET® Signalmaster

VIB 8.306 EX field

multiplexors


(one per string line)

string line 1


MINING applications


Triaxial cable

VIB 90080

Mining: underground mine pumps

VIB 8.306 field

multiplexer

Original photo of pump in Brazilian mine

Control Room

External expert

Internet

PLC Signals: Motor

current, RPM, etc.

Signals: alarm status,

CMS status, etc.

VIBRONET®

Signalmaster string 3

string 2

string 1


GUI – BWE drive 1

YE 1202

M

YE 1102

YE 1101

GE 1207

YE 1203

YE 1204

YE 1106

YE 1201

SE 1007

YE 1105

EE 1114

140° 0° 85°

SE 1113

180° 180°

280°

45°

135°

145°

M1

left

right

Conical gearbox

side

Planetary

gearbox side

Vibration

Gear mesh

Bearings

Machine data

Parameters

operation

Online trends

Alarm System status Trend Diagnostic Back Start

VIBRONET - Online Condition Monitoring Gearbox – drive 1

Connection status

YE - Acceleration

GE - Displacement

SE - RPM

EE - Load


GUI machine level – BWE 546 – SRs 2000

-

LubCos_Ölzustandsüberwachung A

P

-BA_Beschleunigungssensor

-BT_Temperatursensor

-BN_Drehzahlsensor

-

BM_DMS_Momentenmessung

-BP_Drucksensor

M

Momentanwerte

Maschinendaten

BA1101

BA1102

BA1103

BA1104

BT1201

BT1202

BT1203

BT1204

BM1105

Schwingung Kegelritzelwelle oben radial

Schwingung Kegelritzelwelle oben axial

Schwingung Kegelritzelwelle unten radial

Schwingung Kegelritzelwelle unten axial

Temperatur Kegelritzelwelle oben Lager 1

Temperatur Kegelritzelwelle unten Lager 2

Temperatur Kegelritzelwelle unten Lager 1

BT1205 Außentemperatur

Abtriebsmoment

BP1106

BP1107

BT1206

Öldruck vor Filter

Öldruck nach Filter

Ölsumpftemperatur

BN1301 Eingangsdrehzahl

LubCos Ölzustandsüberwachung

Temperatur Kegelritzelwelle oben Lager 2

Warnung Signalanalyse Zurück Startseite Alarm System

Normal

Warning

Alarm

Open Circuit

Disabled

BE1303 Kupplungsschlupf (Temperaturüberschreit.)

VIBROWEB XP - Online Condition Monitoring

Schaufelradbagger 546 – SRs 2000 TAKRAF GmbH

links

rechts

Kegelradseite

Planetenseite

Antrieb 1

(oben)

M

Belchatow / Polen

Antrieb 2

(unten) A P P

Ölfilter


Belt conveyor system – typical defect types

Unbalance Misalignment

Wear

Wear Gear mesh

problem

Broken Teeth

Unbalance

Cracks Deformation

Wear Cracks

Bearing Defect Wear

Electrical

Unbalance Electrical

Motor

Gear Box

Drive Belt

Pulley

PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 111

References: Brazil - Jaguar Mining Inc

* With variable conditions: load and RPM

BALL MILLS:

24 hours a day

7 sensors per mill

2,5MW Siemens motor

Vibration sensor

PRUFTECHNIK VIBROWEB XP

27/04/2013

References: Brazil - Jaguar Mining Inc


Problem:

The shaft was breaking often, causing low machine availability and high maintenance costs

Maintenance was performed in monthly basis (preventive), but the faults didn’t follow a pattern

No information regarding the vibration of the machine

After the implementation of an Online Monitoring System:

Maintenance labours are performed based on the machines vibrations

The shaft hasn’t broken since, hence raising machine availability

Positive feedback from the customer

Monitoring with

Online VIEW

27/04/2013

Some mining references


Mine Device product

Mafube VIBXPERT® II Coal

Phola VIBXPERT® II Coal

Kriel Vibnode Coal

Greenside VIBXPERT® II,

VIBXPERT® EX

Coal

Sishen VIBSCANNER® Iron

AngloAmerican Coal Mines

South Africa

Drummond Company, Inc.

Colombia / VIBROTIP® + VIBCODE®

Evolution Mining

Australia

Mine Device Application

Cracow 1 VIBROWEB®, 2

WEARSCANNER®

Ball mills

Pajingo 1 VIBROWEB®, 2

WEARSCANNER®

Ball mills

27/04/2013

Some mining references


Xstrata

Australia

Mine Device Application

Abbot Point 2 VIBNODE® Stack reclaimer

Mount Isa 1 VIBROWEB®,

1 VIBXPERT® II

Underground jaw crusher

George Fisher 1 VIBROWEB®,

1 VIBXPERT® II

Vertical cone crushers

George Fisher 1 VIBROWEB®,

1 VIBXPERT® II

Vent fans

Zinc VIBNODE® Mobile crane analysis on

crab wheels

Copper 2 VIBROWEB®XP, 1 VIBNODE(R),

1 VIBXPERT®

Anode crane, fans

Oaky No. 01 12 VIBROWEB®, 2 VIBXPERT®II Conveyor belts

Okay North 5 VIBGUARD®, 2 VIBROWEB®XP Longwall monitoring

BHP

Australia / 3 VIBROWEB®XP + 1 VIBXPERT® / Fans

27/04/2013

Mining trucks under control

PRUFTECHNIK Middle East FZE (Dubai) - Robert Schmaus 115

Stand Test with VIBXPERT®II Multiplexer support

Measure during routine visits to the shop

Motor is set to run always at the same constant

speed

MUX and sensors can be installed permanently

on truck

13/03/2013

PRUFTECHNIK Middle East FZE (Dubai) - Robert Schmaus 116

SAG Mill Feed Conveyor: electric motor + FALK gearbox

Example of Conveyor Gearbox monitoring

LAN / Ethernet

Motor:

Power: 300kW / 402 HP

Speed: 1195 RPM

Gearbox:

Output shaft: 66 RPM

Online CMS

13/03/2013


References: special mining equipment*

VATTENFALL Europe Mining – Welzow Süd Mine

Germany / online monitoring of Bucket Wheel

Excavators SRs 6300 & conveyor systems, since

1997

Maritza Mine

Bulgaria / online monitoring of Bucket Wheel

Excavator SRs 4000+VR & conveyor systems

The fourth largest bucket wheel excavator in the

world!

Elektrownia Bełchatów Power Plant

Poland / online monitoring of Bucket Wheel

Excavators SRs 2000 & conveyor systems

QNI – Quensland Nickel

Australia / port crane system online monitoring at

Yabulu refibery

* With variable conditions: load and RPM 27/04/2013


RAW MILL 1 [8]

KILN

FAN

[6] KILN DRIVE

[8]

COOLING FAN

BOOSTER [5] KILN FAN [5]

COAL MILL [9]

CEMENT MILL 2 [7]

CEMENT MILL 3 [7]

DRY FAN [6]

SEPARATOR [7]

RAW MILL SEPARATOR 1 [8]

RAW MILL SEPARATOR 2 [8]

SEPARATOR [7]

CMS

CLINKER CRUSHER

POLYTRACK [5]

Cement: plant monitoring

RAW MILL 2 [8]

SEPARATOR [7]

1 2 3

4 5 6

7

8 9

10 11

12

Vertical Roller Mills (VRM) – measurement locations & parameters (examples)

Typical defects

Drive motor: imbalance, misalignment,

wear

electrical problems, bearing condition

Gear box: gear mesh of pinion and

planetary stage; bearing condition at

drive shaft; oil supply

MIL

LIN

G

SE

PA

RA

TIO

N

Measurement location examples

1-3 = Motor, bearing condition + vibration RMS

4-11 = Gearbox, input, bevel gear, planetary

stage

12 = Torque measurement

Additionally: motor current

Parameters for gearbox:

- Spectra, envelope spectra and vibration

acceleration

- Perform band analysis

Grinding table: Temperature of friction bearing

Optional: mill feed, power, loads, etc

Oil supply:

- Temperature

- Pressure

FLS

AT

OX

Vert

ical R

olle

r M

ill

Accelerometer sensors

Proximity sensors

Torque measurements


http://www.flsmidth.com/MAAG+Gear/English/

Gearbox input shaft

Example of vibration sensor mounted

on gearbox input shaft


Online visualization with OMNITREND® Online View


OPTION: Torque measurement


Installation of Torque measurement point



Reference Letters

Reference letter: Ocean Rig



Oil & Gas: sample reference letter of BP


Summary

- Condition Monitoring is very important for a plant

► Increases plant’s reliability

► Detects machines with problems and helps finding source of failures

► Reduces the number of unnecessary machine stops

► Knowing the failure, repairs can be planned at the most effective time, parts

can be ordered and labor can be organized well in advance

► Ensures machine uptime, decreases loss of production

► Decreases costs for maintenance, costs for stock, reduces energy

consumption of machines... and much more...

► Prevents from safety and environmental issues

► Helps to increase PROFIT of plants

► And...

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PRUFTECHNIK Middle East FZE

- www.pruftechnik-me.com

- www.pruftechnik.ae

PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus

We are close to you. Because we care.

PRUFTECHNIK Middle East / Dubai – UAE / Phone: +971 4 214 6386

online_failure detection

Technology

employees sales turnover

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breakthrough product

utrzymanie ruchu2010

impovation awards2010

company organization

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