Technologies in Manufacturing Maximizing machinery health with - - PowerPoint PPT Presentation

Predictive Monitoring Technologies in Manufacturing

Maximizing machinery health with condition based monitoring

CBM Goals



ZERO unplanned downtime – Maximize Equipment Availability & Reliability

• Plan ALL Maintenance - HOW?



Be competitive today with a plant that is typically more than 40 years old – Extend Machinery Life & Rebuilds Running equipment beyond its design capacity Increased throughput without RISK of machine failure?

Reliability Strategy:

 What maintenance does the machine need during the

next planned shutdown?

– Are the spare parts in my inventory?

 Can the equipment run beyond the next scheduled

• utage?

 Are the machines running without excess vibration?

– Are alignment and balancing work orders needed – Is lubrication proper and adequate – Thermography needed?

What is Vibration?

 Vibration is the motion of a body about a

reference point caused by an undesirable mechanical force.

ISO 10816-3

inch/s RMS mm/s RMS ↖1 ↖25.4 ↖0.433 ↖11 WARNING C ↖0.279 ↖7.1 ↖0.177 ↖4.5 ↖0.137 ↖3.5 ↖0.11 ↖2.8 ↖0.09 ↖2.3 ↖0.055 ↖1.4 rigid flexible rigid flexible A C B D Notes: D GOOD VERY BAD ALARM 2 - The shaft hight of a machine with raised feet, or any vertical machine , is to be taken as the shaft height of a machine in the same basic frame, but the horizontal shaft foot-mounting type. When frame is unknown, half the machine diameter should be used. motor center hight 160mm < H < 315 H > 315 1 - The shaft hight, H of a machine is the distance between the centerline of the shaft and the baseplate of the machine VERY GOOD A medium sized machines large sized machines Normal Operation Unsatisfactory New Machine Condition Damage Occuring group / class group 2 15kw <300kw group 1 300kw <50 mw VELOCITY 10-1000hz >600rpm VELOCITY 2-1000hz >120rpm foundation type machine type B

Rules of Vibration Analysis

 Each machine fault generates a specific vibration

pattern

 The frequency is determined by machine speed

and design

 The “FFT” process is used to separate a vibration

signal into information about individual faults

FFT Spectrum Analysis

Frequency amplitude

FFT Spectrum

shows component vibration signals at their respective frequencies

Spectrum Analysis Techniques



Collect Useful Information



Analyze

Spectrum Analysis Techniques



Collect Useful Information



Analyze

1800 RPM gearbox gearmesh frequencies 2400 RPM 5 blade fan motor

A Typical FFT Spectrum

Specific peaks typically correlate to Specific machine faults Related to machine speed

MOA POA POH POV PIH PIV MIH MIV MOH MOV

2 per bearing + 1 axial measurement per shaft

Measurement Point Locations

Three Rules of Diagnosis

 Each machine fault generates a specific

vibration pattern.

 The frequency of the vibration is determined by

the machine geometry and operating speed.

 A single vibration measurement provides

information about multiple components

Diagnosing Machine Faults

 Imbalance  Misalignment  General looseness or wear  Bearing defects  Gear defects  and many more...

What is a Vibration Program?

 Expertise, Technology, and Work Processes that

– Prevent Unexpected Downtime

• By assuring machines do not fail catastrophically

– Extend Machine Life and Optimize Performance

• By detecting & correcting root cause conditions that cause

excessive wear

– Allow You To Work Efficiently

• By trending progressing faults and…
• Coordinating repairs to occur at planned outages

Do the right work… At the right time… With the right methods…

So what can Vibration Analysis detect?

 Track progressing stages of Bearing Failure  Identify/correct Imbalance and Misalignment  Identify/correct Resonance  Identify Mechanical Wear in couplings, bearings, support

structures, etc.

 Detect other defects such as:

– Lube failure / soft foot / broken rotor bars – Pump cavitation, and many more…

Case Histories-continuous monitoring



Cement Mill:

– On-line vibration monitoring detect resonant condition – Air handler with intermittent high vibration

• Resonance occurs when baffle open at ~61%.



Power Plant:

– On-line vibration extends maintenance intervals

• Preventive turbine maintenance every 5 years

– Unnecessary maintenance can induce faults!

• Extend from 6 – 10 years with on-line monitoring

– Average repair cost around $1 million

Case Histories-continuous monitoring



Automotive Plant:

– On-line vibration monitoring ensures quality

• Continuous display of machine tool condition

– Monitoring tool tip – Plan change-outs during shift changes. – Confirm quality of rebuilds



Waste Water Facility:

– On-line vibration helps with compliance

• Spill risk is minimized
• Operators are notified immediately of upset
• Mandatory condition assessments of all equipment

Case Histories-monitoring peak and phase



Decanter Plant Centrifuge:

– One times turning speed

• Phase is same
• Peak amplitude changes
• Diagnosis?



Balancing Stand:

– Peak vibration is same – Phase changes – Diagnosis?

Case Histories-Inspection with Strobe Light



Textile Plant: High 1x vibration on



Pulley assembly. Strobe inspection



Showed damaged pulley on motor Polyester Plant: Plant balanced fan twice to eliminate high 1x vib Strobe inspection showed cracked Fan fin inside motor fan guard

Case Histories- Coherence



Nonwoven Plant:



High floor vibration at 565 RPM



What is cause



Strobed the equipment room



Air handler fan stopped



Belt dressing on top of pully cage



Coherence test showed .95



Correlation



Fan inspection showed damaged



Blade



Plant had moved equipment from



area

Case Histories-Cracked end ring on motor



Automotive Plant:



400 Ton Refrigeration unit



1x peak was growing with temp



Amp draw guage flickering back



And forth

Where should predictive maintenance be used?



Preventive

– Support equipment

Predictive Critical & Essential Preventive Essential Reactive Non- essential

0% 20% 40% 60% 80% 100% Plant Equipment



Predictive

– Critical to production



Reactive

– Easy/Inexpensive to replace

Elements of a Condition monitoring Program

Diagnostic and corrective tools

Training Services

7) Document Business & Maintenance Implications

 Document:

– Diagnoses – Recommendations – Accuracy – Reoccurring faults – Mean time between service – Production gains – Cost savings – Financial impact

Summary: Key Points in a CBM Program

 Expertise, Technology, and Work Processes that

– Prevent Unexpected Downtime

• By assuring machines do not fail catastrophically

– Extend Machine Life and Optimize Performance

• By detecting & correcting root cause conditions that cause

excessive wear

– Allow You To Work Efficiently

• By trending progressing faults and…
• Coordinating repairs to occur at planned outages