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Lecture Note Introduction to Condition Monitoring
Prepared by Essam Abdel-Halim Moustafa
Abstract This lecture introduces the predictive maintenance concept of condition monitoring for industrial rotating machines. This makes it easier to understand how important the need for condition monitoring is.
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Introduction to Condition Monitoring
Condition monitoring (CM), by definition, is simply a technique for routinely evaluating the condition of equipment. This simple definition, however, has tremendous applications in improving the life of many industries and even our day-to-day existence. It is instrumental in increasing industrial production and profitability, improving product quality, reducing environmental pollution, improving safety, and reducing the waste of our limited natural resources. Spectacular gains can be made in all of these areas, if CM is properly employed. If not, it could equally generate losses. CM can be done on almost any kind of device from micro-sized circuit boards to huge 1000 MW hydroelectric turbines. Nearly every imaginable industry can use or is using some form of CM. This lecture will touch on several important topics which concern CM, but the focus will be on industrial applications using rotating machinery.
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Types of Maintenance Break-down
Corrective Maintenance
Cost
(Run-to-breakdown) Repair it when it fails
Preventive Maintenance (Time Based Maintenance) Maintenance at regular intervals
Cost
Predictive Maintenance (On Condition Maintenance) Problem detected before predicted failure. Maintenance planned ahead
Cost
Time
Time
Time
Maintenance has evolved from run-to-breakdown methods, to time-based methods to modern predictive maintenance practices. This has resulted in less spares and manpower to maintain machines, and higher machine availability.
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Corrective Maintenance -Run to BreakdownNot recommended for critical machines
Corrective CorrectiveMaintenance Maintenance leads leadsto: to: Secondary Secondarydamage damage Safety Safetyrisk risk
Cost
Unplanned Unplanneddowntime downtime Unplanned Unplanned maintenance maintenance Product Productwaste waste Spares inventory Spares inventory
Break -down
Time
Which is historically the first maintenance strategy employed. A machine is repaired only after a failure has occurred. This is a very expensive maintenance management scheme, since it requires: high spare parts inventory, high machine downtime, high overtime labor costs, and low production availability.
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Preventive Maintenance Time Based Maintenance
Not recommended for critical machines
Time-based Time-based Preventive Preventive Maintenance Maintenance involves: involves: More Morefrequent frequentoverhauls overhauls Risk of early failures Risk of early failures Tampering Tamperingwith withgood good machines machines Time Timeconsuming consumingoverhauls overhauls Experts needed for Experts needed foreach each overhaul overhaul
Where important machines are not fully duplicated or where unscheduled production stops can result in large losses, maintenance operations are often performed at fixed time-intervals. The advantage of this maintenance strategy is that it is planned strategy and is based on previous experience and the mean-time-between-failure (MTBF) statistic for the machine. The disadvantage of this maintenance scheme is that it is not based on the condition of the machine, but rather on the time elapsed since the previous maintenance occurred. Thus a failure may occur before a maintenance is performed, as in Run-ToBreakdown maintenance, or a perfectly operating machine may be maintained with a consequent waste in labor and material . This system is therefore called Time-based Predictive Maintenance.
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Predictive Maintenance On-condition -Maintenance
Recommended for critical machines
Monitor Monitorthe thecondition conditionof ofthe the machine and predict when machine and predict whenitit would wouldfail fail Plan maintenance Plan maintenanceahead aheadof of time and save money time and save money Repair Repairthe themachines machinesonly only when they need when they needto to Focus Focusoverhauls overhaulsonly onlyon onfaulty faulty parts parts ☺☺ Higher Higherplant plantavailability, availability,
performance performanceand andreliability reliability ☺☺ Greater safety Greater safety ☺☺ Better Betterproduct productquality quality ☺☺ Attention to environment Attention to environment ☺☺ Longer Longerequipment equipmentlife life ☺☺ Greater cost effectiveness Greater cost effectiveness
In which maintenance is performed on the basis of the machine condition. This is done by monitoring the machine condition. Any change in condition is detected, and the time to Failure is estimated . This is also accompanied by diagnosing the cause of the fault to actually pin point the defective components. With this method each machine is considered individually by making fixed-interval condition measurements to obtain a quantitative value of the “Health” of the machine. In this way maintenance is only allowed when measurements show it to be necessary.
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Comparison of Maintenance Strategies Run-to-breakdown
Preventive
Predictive
Method
Failure based
Time based
Condition Based
Premise
No maintenance
MTBF
As-Needed
Advantages
•No maintenance cost
•Planned Maintenance. •Structured program
Disadvantages
Use
•High spare parts inventory •High machine downtime •High overtime labor costs •low production availability
Used only on cheap, abundant and insignificant components
•Failure may occur before scheduled maintenance. •Maintenance may be performed unnecessarily. •Maintenance may cause failure. Used on all machines
• Lower maintenance costs . •Fewer machine failures. •Less repair downtime. •Reduced inventory. •Longer machine life. •Increased production. •Improved operator safety. •Verification of new equipment condition. •Improved overall profitability. •Initial investment in equipment
Used on all machines
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Why Make Condition Monitoring ?
Initial investigations, selection of monitoring points, establishment of limits Selection and purchase of instrumentation Training
Yes
No
Condition Monitoring
Longer time between overhauls Reduced repair duration Reduction of spare-part stock Less unexpected breakdowns Elimination of secondary damage Reduction in business interruption and damage insurance premiums
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Predictive Maintenance Flow Chart Start
Reference creation Regular Measurements No
Machine Specs. & Drawings
Fault detected Yes Fault diagnosis
Troubleshooting Chart
Fault correction
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Machine Potential Failures Analysis
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Yes
Out of Balance Misalignment / Bent Shaft
Yes
Damage of rolling elements bearings
Yes
Damage of journal bearing
Yes
Damage of gearboxes
Yes Yes Yes
Yes
Yes
Yes
Yes
Yes
Yes Yes
Belt Problems Motor Problems Mechanical Looseness Resonance
Vi br at io n
Cu rre nt
Oi la na ly si s
Fl ow
Type of machine fault
Pr es su re
Parameters
Te m p.
Parameters Used for Detection of machine Faults
Yes
Yes Yes Yes
Why Vibration ? Vibration is used as the fault detection parameter simply because it can give an early warnings of fault development for a wider variety of typical rotating machinery faults. Other detection techniques, if used in isolation, limit the variety of faults, and so unexpected breakdown by a fault type not included, is a real possibility.
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What is Vibration
Force •Forces caused by -Imbalance - Friction -Shock -Acoustic Input Forces
Mobility
Freq.
•Structural Parameters: -Mass -Stiffness -Damping
x System Response (Mobility)
=
x
Freq.
Vibration
= •Vibration Parameters: -Acceleration -Velocity -Displacement
Vibration Freq.
What is Vibration? Vibration is mechanical oscillation about a reference position. Vibration is an everyday phenomenon, we meet it in our homes, during transport and at work. Vibration is often a destructive and annoying side effect of a useful process, but is sometimes generated intentionally to perform a task. Vibration of machines Vibration is a result of dynamic forces in machines which have moving parts and in structures which are connected to the machine. Different parts of the machine will vibrate with various frequencies and amplitudes. Vibration causes wear and fatigue. It is often responsible for the ultimate breakdown of the machine.
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Signal level Descriptors Amplitude
T
Peak
RMS
Average
PeakPeak
RMS =
1 T 2 x ( t )dt T ∫0
Time
Average =
1 T x( t ) dt T ∫0
Crest Factor :
Peak RMS
Signal Level Descriptors The level of vibration signal can be described in different ways. Peak and peak-to-peak values are often used to describe the level of a vibration signal since they indicate the maximum excursion from equilibrium position. The RMS (Root Mean Square) level is a very good descriptor, since it is a measure of the energy content of the vibration signal.
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Time Signal Descriptors Amplitude
PeakPeak
Peak RMS Average Time
RMS =
1 T 2 x ( t )dt T ∫0
Average =
1 T x( t ) dt T ∫0
Crest Factor :
Peak RMS
Time Signal Descriptors These descriptors are not only used in conjunction with a single sinusoidal signal but also with normal machine vibration signals which are composed of many sinusoidal vibration components.
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FFT transformation Displacement
d = D sinωnt Displacement
D Time
Frequency
1 T
T Period, Tn in [sec] m
1
Frequency, fn= T in [Hz = 1/sec] n
k
ωn= 2 π fn =
k m
Mass and Spring Once a (theoretical) system of a mass and a spring is set in motion it will continue this motion with constant frequency and amplitude. The system is said to oscillate with a sinusoidal waveform. The Sine Curve The sine curve which emerges when a mass and a spring oscillate can be described by its amplitude (D) and period (T). Frequency is defined as the number of cycles per second and is equal to the reciprocal of the period. By multiplying the frequency by 2 π the angular frequency is obtained, which is again proportional to the square root of spring constant k divided by mass m. The frequency of oscillation is called the natural frequency fn. The whole sine wave can be described by the formula d = Dsin ωnt, where d = instantaneous displacement and D = peak displacement.
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Spectrum Analysis
We see that the longer the period of the sine wave, the lower the frequency. The magnitude of the peak in the spectrum corresponds to the energy content of the sine wave (RMS).
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Vibration Parameters Displacement
Velocity
Acceleration
m
d v
k
a
c
F=k×d
F=c×v
m
F=m×a
Mechanical Parameters Before going into a discussion about vibration measurement and analysis, we will examine the basic mechanical parameters and components and how they interact. All mechanical systems contain the three basic components: spring, damper, and mass. When each of these in turn is exposed to a constant force they react with a constant displacement, a constant velocity and a constant acceleration respectively.
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Acceleration, Velocity and Displacement
a v
M d
a v
Acceleration
d M M
a
a
Velocity m
v
v
d m
m
Displacement
d
Time (Simple vibration)
Frequency (real machine)
Vibration may be measured in acceleration, velocity or displacement. For higher frequencies the velocity is higher than the displacement, and acceleration is higher than velocity. Note that the peaks in the three spectra from a real machine are situated at the same frequencies. For very high frequencies, the peaks may not be seen in the displacement spectra due to noise.
Which Parameter to Choose? If the type of measurement being carried out does not call for a particular parameter to be measured e.g. due to some standard, the general rule is that the parameter giving the flattest response over the frequency range of interest should be chosen. This will give the biggest dynamic range of the whole measurement set up. If the frequency response is not known start by choosing velocity.
An advantage of the accelerometer is that its electrical output can be integrated to give velocity and displacement signals. This is important since it is best to perform the analysis on the signal which has the flattest spectrum. If a spectrum is not reasonably flat, the contribution of components lying well below the mean level, will be less noticeable. In the case of overall measurements, smaller components might pass completely undetected. Use the Flattest Spectrum In most cases this will mean that velocity is used as the detection parameter on machine measurements. On some occasions acceleration may also be suitable, although most machines will exhibit large vibration accelerations only at high frequencies. It is rare to find displacement spectra which are flat over a wide frequency range, since most machines will only exhibit large vibration displacements at low frequencies. In the absence of frequency analysis instrumentation to initially check the spectra, it is safest to make velocity measurements (but still using the accelerometer, of course, since even the integrated accelerometer signal gives a better dynamic and frequency range than the velocity transducer signal).
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Man-Machine Link Correct & Effective Maintenance Decision
M/C Information & Operation
Diagnostic Knowledge
+ + +
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Example of Machine Information table
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Example of Machine Component
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Frequency Spectrum Motor Speed
: 600 r.p.m
Rigid Coupling-1: No. of bolts 4 Co First gear
:50 :50 teeth
Second gear
:20 :20 teeth
Rigid Coupling-2: No. of bolts 6 Co :5
Vib.
Fan blades
r.p.m or (Hz)
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Frequency Spectrum interpretation Motor Speed
: 600 r.p.m
Rigid Coupling-1 : No. of bolts 4 Co First gear
: 50 teeth
Second gear
: 20 teeth
Rigid Coupling-2 : No. of bolts 6 Co :5 5 blades
5 75 Bla 00 d e rp s X m (1 15 25 00 Hz ) 6B 90 00 olt X rpm 15 (15 00 0H z)
4 24 Bo 00 lt X r p 60 m 0 (4 0H z)
600 r.p.m (10 Hz) 15 (2 00 5 r.p Hz .m )
Vib.
Fan blades
Gear Meshing Freq. 50 teeth x600 Or 20 teeth x 1500 30,000 rpm(500Hz)
r.p.m or (Hz)
Motor Running Speed Freq.
: 600 r.p.m (10 Hz)
First Coupling defect Frequency
: 600 r.p.m x 4 bolt = 2400 r.p.m(40 Hz)
Gear Meshing Frequency
: 600 r.p.m x 50 teeth=30,000 r.p.m(500Hz) : or 1500 r.p.m x 20 teeth=30,000 r.p.m (500 Hz)
Second shaft speed
: 600x50/20 =1500 r.p.m
Second Coupling defect Frequency :1500 r.p.m x 6 bolt = 9000 r.p.m(150 Hz) Blade Passing Frequency
: 1500 r.p.m x 5 Blade=7500 r.p.m (125Hz)
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Measuring Points
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Vib.
Reference Spectrum
r.p.m or (Hz)
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Overall Alarm
Vib.
Frequency Spectrum With Overall Alarm & Danger
r.p.m or (Hz)
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Band Alarm
Vib.
Frequency Spectrum With Band Alarm & Danger
r.p.m or (Hz)
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Vib.
Example of Bands alarm Sheet
r.p.m or (Hz)
Band No. Band 1
Band 2
Definitions BAND Freq. MIN BAND Freq. MAX BAND ALARM BAND DANGER BAND Freq. MIN BAND Freq. MAX BAND ALARM BAND DANGER
Suggested Setup
!? !? !? !?
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Profile or Narrow band alarm
Vib.
Frequency Spectrum With Profile Alarm & Danger
r.p.m or (Hz)
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Vib.
Overall Analysis
r.p.m or (Hz)
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Frequency Spectrum or Overall Level Frequency Spectrum Vibration
Overall Level 4
5 4 3 2 1
2
5
3
1
Fan Frequency
Date 5 1 2 3 4
Frequency
Date
Vibration 5 4 3 2 1
Gearbox
Frequency Spectrum or Overall Level To decide whether monitoring or testing of the overall level is sufficient or a complete frequency spectrum is required, the engineer must know his machine and something about the most likely faults to occur or which part of the object is of interest. The illustration shows two different situations in monitoring, but it might as well be testing: Monitoring of a fan: The most likely fault to occur is unbalance, which will give an increase in the vibration level at the speed of rotation. This will normally also be the highest level in the spectrum. To see if unbalance is developing, it is therefore sufficient to measure the overall level at regular intervals. The overall level will reflect the increase just as well as the spectrum. Monitoring of a gearbox: Damaged or worn gears will show up as an increase in the vibration level at the tooth meshing frequencies (shaft RPM number of teeth) and their harmonics. The levels at these frequencies are normally much lower than the highest level in the frequency spectrum, so it is necessary to use a full spectrum comparison to reveal a developing fault. A general rule is overall measurements are permissible for simple, non critical machines, while more complex, more critical machinery requires spectral analysis.
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END
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