Vibration Analysis, Emerson Makes it Easy for You

Introduction to Portable Introduction to Portable Vibration AnalysisVibration AnalysisDieter CharleBDM Portable Reliability Solutions | Europe

5/11/2015

Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 2

US $24.5 Billion in Sales

Emerson At-A-Glance 2015

Manufacturing and/or sales presence

in more than 150 countries

220 manufacturing locations around the world

No. 121 on 2014 FORTUNE 500 list of

America’s largest corporations

Founded in 1890NYSE: EMR

Headquarters in St. Louis, Missouri USA

Diversified global manufacturer and technology provider

Approximately 115,000 employees

worldwide


Emerson Invests in New Technology Development to Meet Customer Needs

$805 million … Emerson’s investment in Engineering & Development during 2015

1,900+ … patents awarded in 2015 to Emerson businesses


US & CanadaSales $11.2 BillionEmployees 32,000

Locations 75

Latin AmericaSales $1.5 BillionEmployees 18,000

Locations 30

Western EuropeSales $3.8 BillionEmployees 16,000

Locations 45

Middle East & AfricaSales $1.5 BillionEmployees 1,000

Locations 5

Eastern Europe & RussiaSales $1.0 BillionEmployees 9,000

Locations 15

AsiaSales $5.5 BillionEmployees 39,000

Locations 50

Note: Locations include manufacturing locations only.

Our Business Objective To design, engineer, manufacture, sell and support

our products and solutions in every region of the world

Emerson Global Presence 2015


Our Industry Challenges• Eliminate unplanned production shutdowns

– Minimize exposure – safer work environment – Improved uptime

• Prioritize and plan maintenance actions• Extend time between planned shutdowns• Reduce inventory costs• Increase availability and performance of assets• Reduce preventive maintenance

MotorsMotors PumpsPumps TurbinesTurbinesGearboxesGearboxes


Emerson’s Reliability Solutions


Portable Vibration Analysis – Industry Requirements• Easy Routine Data Collection

• Get Faster Diagnoses- Coherence case history- Complex, hard to access machinery

• Advanced Diagnostics- Detect misalignment during operation- Live monitoring sleeve bearings- Commissioning smaller turbines- Structural Analysis

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Vibration Analysis"Of all the parameters that can be measured non-intrusively in industry today, the one containing the most information is the vibration signature.“- Art Crawford, Consultant / Author -

In one study, nearly two thirds of the entire benefit from Machinery Health Monitoring came from Vibration Analysis- John E. Amos Power Station -

65% VibrationAnalysis


Vibration Analysis – Basic Principle• Mechanical faults generate unique vibration

– Geometry of the machine• diameter of the shaft• number of bearing elements• Type of bearing elements

– Turning speed (e.g. RPM)

High

L

ow

Mechanical Defects detected with vibration analysis

Belt drive faultsImbalanceMisalignmentBent shaftShaft RubLoosenessMachine resonanceBearing Defects including:

•cage defect•outer race defect•inner race defect•rolling element defect

Gear defectsElectrical faults

Cavitation Lubrication


Vibration from Mechanical Faults



Imbalance1 x RPM



Blade Pass4 x RPM



Gear Mesh17 x RPM



Blade Pass4 x RPM

Gear Mesh17 x RPM

+

Imbalance1 x RPM

+


Frequency

Am

plitu

de

How the Vibration Spectrum is Created

Time

Am

plitu

deTime

Am

plitu

de


Roller Bearing FaultsFour different bearing frequencies

Ball Pass FrequencyInner Race

(BPFI)

Ball Pass Frequency Outer Race

(BPFO)

Ball Spin Frequency(BSF)

Fundamental TrainFrequency

(FTF)


How Bearing Faults Generate Vibration


One tool to WIN all challengesIndustry Requirements Modular Multi-Technology Platform

Easy Routine Data Collection • Vibration Routes• PeakVue Analysis

Get Data Faster

- Coherence case history- Complex, hard to access machinery

• 4-channel Analysis• In-field Alarming• Fault Frequencies• Parameter Trending

Advanced Diagnostics

- Detect misalignment during operation- Live monitoring sleeve bearings- Commissioning smaller turbines- Structural Analysis

• Cross Channel Analysis• Vibration Analysis/Troubleshooting• AC Motor Rotor Bar Analysis• 4-Plane Balancing• Dual Orbit Plotting• Transient Analysis• ODS/Modal Analysis

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Lower Cost = Earlier Warning = PeakVue

PeakVue is easy!• One single value to interpret• Earlier warning than any other

technology• Indication of fault and severity

Progression of a Typical Machine Problem

PeakVueAlert

Equi

pmen

t Hea

lth

Time

EquipmentEquipmentFailureFailure

PeakVuealert Oil

analysisTemperaturemonitoring

OverallVibration

Audiblenoise

Hot totouch

SpectrumAnalysis

Vibrationanalysis

Con

sequ

ence

Time

Easy


Vibrationin/s mm/s Minimal Warning

0.15 / 3.7 Good

0.15 / 3.7 Good

0.15 / 3.8 Good

0.16 / 4.0 Good?

0.18 / 4.5 OK?

0.30 / 7.5 Failure occurs!!!

Ons

et o

fFa

ult

Bear

ing

Failu

re

FAULTFAULT

ALERTALERT

FAULTFAULT

ALERTALERT

NoWarning!

Tim

e To

Pla

n

PeakVueg’s Early Warning with Severity

0 Good

10 Alert – Notify maintenance

20 Problem getting serious.

30 Near end of life

40 Take action! Bearing failure imminent

50 Failure occurs!!! 0

10

20

30

50

40

0.0

0.1

0.2

0.3

0.4

0.5

Peak

Vue

(g’s

)Vi

brat

ion

0.0

2.5

5.0

7.5

12.5

9.0

Afte

rRe

pair

Overall Vibration vs. PeakVue Easy


PeakVue is EasyTwo Simple Rules:

PeakVue(g’s)

Interpretation

0 Good machine

10 Some Issue

20 Serious problem

40 Action Point

Reliability 101 for Operators

2. Rule of 10’s• 10 – something’s happening• 20 – something serious happening• 40 – time to take action

1. Zero PrinciplePeakVue on a good machineis at or close to zero

Easy


The magic behind Vibration Analysis

Enveloping registers (Demodulation)

Raw measurement data - Waveform

Signal after rectifying

Signal after band pass filter

Easy


The magic behind Vibration AnalysisPeakVue

Peak Impact Detection registers

Raw measurement data - Waveform

Signal after rectifying

Signal after band pass filter

Easy

PeakVue:

-Keep High Frequency Sample-No Low Pass Filter


The magic behind PeakVuePeak Impact Detection registersEnveloping registers (Demodulation)

1000 Hz

200Hz 8 g’s 108g’s

50Hz >1 g108g’s

28 g’s 108g’sDemodulation

AmplitudePeakVue

Amplitude

Bandwidth G’s Error G’s Error

1000 Hz 28 74% 108 0%

200 Hz 8 92% 108 0%

50 Hz 0.5 99% 108 0%

Easy


PeakVue Case Study – Outer Race Defect359 RPM

Peak Impact Detection registersEnveloping registers (Demodulation)


Five Inputs / Eight Live PlotsFive Inputs:

Channel 1 Channel 2 Channel 3 Channel 4 Plus Tachometer

8 live plots


Patented Emerson Triax = Easy and Fast! Fast


Where to Use Triax or 4 Channels?

• Everywhere in Route Mode

– Easier

– Faster

Example: Paper Plants (dryer section)

• Turbines Start-up (need to see phase info at both planes, so 4 Channels+Phase)

• All Advanced Applications Where Cross Channel Data is Needed

Fast

Advanced

Advanced



SpeedVue = Easy and Fast Fast

Measure rotating speed without reflecting tape?

Yes, it is possible!

Laser speed sensor Measure surface shape of shaft Calculates the rotation speed


In Field Analysis• Colored parameter alarms, provide

immediate indication of Machinery Health

• See what parameter is in alarm and its severity immediately at the point of data collection

• Fault Frequencies help identify the source of the vibration

• Fault Frequencies help identify the source of the vibration

Parameter Alarms

Fast

Fault Frequencies

FaultFreq

A A A A B B B B

M1H - RPMMay 2007 – July 2007

Ampl: 1713.47 June 12 2007

NextTrend

PrevTrend

Trend


Analysis Tools in the Field• Analysis Experts are preconfigured so even a novice can use them.• Allows troubleshooting tests to be performed while next to the

machine without making a return trip

Advanced


Four Voltage Channels + Tachometer

Dual Orbits!Dual Orbits!

Advanced


Orbit Plots: Monitor 2 Sleeve Bearings• True Orbit Plot

– Measure displacement– 2x dual eddy current sensors @ 90° apart

Advanced


Four Voltage Channels + Tachometer

andandFour Accelerometer Four Accelerometer

Channels + TachometerChannels + Tachometer

Advanced


Transient analysis

Analyze the detailed spectrum and waveform by sliding of interest bar

Advanced


Laser Shaft Alignment

Use my analyzer tool forsimple & advanced Shaft Alignment?


Via Bleutooth CommunicationBasic and Advanced Modes

- Add compensation factors- Full or Partial Sweep

Advanced


Single and Multi Plane BalancingAdvanced

Use my analyzer tool for simple & advanced balancing jobs ?


Laser position sensor + tape Acquire reference run dataAdd or remove trail weights (plane 1, 2, etc)View balance correctionCollect trim run data for corrected condition


Cross-Channel PhaseCheck for Misalignment

– Measure across a coupling– Check phase at running speed

Advanced


Structural Analysis OptionsAdvanced

• Operating Deflection Shape– Performed while machine in operation– Single frequency (typically running speed) measurement– Can be performed with any CSI machinery analyzer– Four channel is recommended– Measures actual amplitude of deflection– Shows how machine deflects in normal operation

• Modal Analysis– Requires machine to be shut down– Analysis across all frequencies– Requires dual or four channel CSI 2140 for measurements– With 4 channels: 1 channel is reference + triax– Determines ratio of response to input, no absolute amplitudes– Detailed model of machine stiffness, resonances, etc.


ODS on Piping• Triax sensor + ODS offers more

locations to collect data

• Due to Triax no more Software interpolation required

Advanced


Some other ODS-examplesAdvanced


Modal Analysis or Coherence Case History• Verify if vibration is related across points• Reoccurring failure on paper machine

– Unusual vibration present– Matched turning speed of pump below

• Coherence measurement– proved that vibration was related

• Fixing pump operation– solved paper machine problems

Advanced


Resonance• Natural frequencies are directional• So, you need to measure in Horizontal, Vertical and Axial direction.• With CSI 2140, all directions can be measured simultaneously• For hammer impact tests, your hammer is channel 4

Advanced

MOTOR


Impact Test Application• Structural Analysis

– Identify resonances– Measure stiffness – Determine system response– Modal analysis

• Use One Hammer and Three Accelerometers

• Use One Hammer and One Triax Sensor

MOTOR

Advanced

Ergonomics and Ergonomics and FeaturesFeatures

CSI2140

The Portable Vibration Analyzer

of the future


Screen & Keyboard

Automatic Backlight

Backlit Keyboard

Huge LCD Display

Touchscreen – glove compatible!


00998877665544332211009988776655443322110099

Thin Profile

66554433 mm


Built-in Stand


Comfortable New Strap


Communications

Ethernet PortWi-Fi to AMS

Machinery Manager

Bluetooth toaccessories

Ethernet

USB 2.0

Wi-Fi

Load Routes using USB Memory Stick


Remove Wires to Increase Safety

>>>>>>>>>>>>>> >>>>>>>>>>>>>>

Customer Quote: “The fact is, today none of my vibration techs

would do a route without headphones.”


E-mail Route/Data Files• Upload data to local PC with FREE

software• E-mail, FTP, or copy across network

from remote location to database or SME for archive and analysis


Li-ION Battery - Full 10 Hour Shift

External Charger

8 Hr24 Hr

Car Charger


Memory

1GB

InternalExternal32GB SD card


New Accessories• CSI 2140 4-Channel Input Adapter

(Accel & Volts)

• Splitter Cables for 4-Channel

• Car Charger

• Bluetooth Wireless Headphones

• External Battery Charger

Questions?Questions?Dieter CharleBDM Portable Reliability Solutions | Europe

[email protected]

+32 493 229 991

mailto:[email protected]