CSI 4500 Machinery Health Monitor Overview Jon Hall Novaspect, Inc.
Failure Curve Infant Mortality
Expected Life
End of Life
Probability of Failure
Protection System
Time
Failure Curve Infant Mortality
Expected Life
Probability of Failure
Predictive System
End of Life Protection System
Failure
sion s e r og lt Pr u a F
Time
Control Room Online Watch
Maintenance Engineering AMS Machinery Online Watch Manager
PDM Group AMS Machinery Manager
Plant Network
MHM Server Dedicated Ethernet
JBOX
JBOX
JBOX JBOX
JBOX
JBOX
JBOX JBOX
JBOX
JBOX
Control Room Online Watch
Maintenance Engineering AMS Machinery Online Watch Manager
PDM Group AMS Machinery Manager
Plant Network
MHM Server Dedicated Ethernet
JBOX
JBOX
JBOX JBOX
JBOX
JBOX
JBOX JBOX
JBOX
JBOX
Why Online/Continuous Monitoring z z
Critical Equipment Hard to Access – Distance – Safety
z z
Man Power Repeatability
Protection System z z
z
Normally based on overall vibration levels Designed to prevent additional damage after failure REACTIVE
Predictive System z z
z z
Identifies faults prior to failures. Allows for planning to repair fault, or correct a condition that will lead to a fault. Allows user to track the progression of faults PROACTIVE
Machinery Applications in a Typical Plant Total # Machines 2,500 Typical Industrial Process Plant
Turbines Generators Compressors
Motors Pumps Fans Gears
~125 Machines
~625 Machines
5% Critical
25% Essential
Online Monitoring
CSI 4500 Monitor
Loss of machine means > 40% lost plant capacity
CSI 9210 Transmitter
Automated Data Collection Periodic Data Collection
~750 Machines
~500 Machines ~500 Machines
30% Important
20% Secondary 20% Non-Essential
Portable Portable
CSI 2130 Analyzer
Run to Fail
Introduction to vibration z
z
Vibration – The motion of a body about a reference point At it’s simplest, vibration is displayed as displacement over time, in Mils.
Simple Vibration at 60 Hz - Displacement 1.5
Period 1
0.5
Displacement 60Hz
0
-0.5
-1
Amplitude -1.5
Freq= 1/Period
Velocity at 180 Hz 1.5
1
0.5
0
-0.5
-1
-1.5
Displacement 180Hz Velocity 180 Hz
Acceleration – Rate of Change of Velocity 1.5
1
0.5
Displacement 60Hz 0
Velocity 60 Hz Acceleration 60Hz
-0.5
-1
-1.5
The units z
z
z
z
Displacement accentuates the low frequencies - Mils Acceleration accentuates the higher frequencies (g’s) Velocity is consistent across all frequencies (in/sec or mm/sec) Most vibration is analyzed in Velocity
Types of Data – Time Waveform 1.5
1
0.5
Turning Speed
0
-0.5
-1
-1.5
Turning Speed Time Waveform
Types of Data – Time Waveform 1.5
1
0.5
Turning Speed
0
2x TS
-0.5
-1
-1.5
Add twice turning speed vibration
Types of Data – Time Waveform 1.5
1
0.5
Turning Speed 2x TS
0
7x TS
-0.5
-1
-1.5
Add blade pass vibration
Types of Data – Time Waveform 1.5
1
0.5
Turning Speed 2x TS
0
7x TS Brg
-0.5
-1
-1.5
Add Bearing Vibration
Types of Data – Time Waveform Total Vibration 3
2
1
0
Total Vibration
-1
-2
-3
Complex Time Waveform
If all machines are frequency generators, Then what components would I expect to see?
If all machines are frequency generators, Then what components would I expect to see?
Collection of Data … Data… What would I expect to see?
Component
Frequency RPM
Hz ( / 60)
Orders (Motor Speed)
1800 720 900 4 x 900
30 12 15 4 x 15
1.0 0.4 0.5 4 x 0.5
1. BPFI
10,638
177.3
5.91
2. BPFO
7,362
122.7
4.09
3. BSF
4,752
79.2
2.64
4. Cage
736
12.3
0.409
Structure
420
7
0.23
Motor Belts Fan Shaft Fan Blades Roller Brgs
Collection of Data … Data… What would I expect to see?
Component
Frequency RPM
Hz ( / 60)
Orders (Motor Speed)
1800 720 900 4 x 900
30 12 15 4 x 15
1.0 0.4 0.5 4 x 0.5
1. BPFI
10,638
177.3
5.91
2. BPFO
7,362
122.7
4.09
3. BSF
4,752
79.2
2.64
4. Cage
736
12.3
0.409
Structure
420
7
0.23
Motor Belts Fan Shaft Fan Blades Roller Brgs
A Typical Waveform
Need Spectrum Analyzer for diagnostics, not just Overall vibration meter
Types of Data - Spectrum z
z
The complex time waveform is difficult to analyze. A Fourier transform is performed on the waveform to put the data is a format that is easier to understand,
3
2
1
0
-1
-2
-3
Complex Time Waveform
Types of Data - Spectrum The Fast Fourier Transform (FFT) takes the complex waveform and breaks it down into the component sine waves 3
1.5
2
1
1
0.5
0
FFT
0
-1
-0.5
-2
-1
-3
-1.5
The amplitudes for each sine wave is then plotted at the frequency of the sine wave, creating the Spectum
Spectrum (Fast Fourier Transform) Spectrum (FFT) 1.4
Twice Turning Speed
1.2
Turning Speed 1
0.8
0.6
Blade Pass 0.4
Bearing Frequency 0.2
397
386
375
364
353
342
331
320
309
298
287
276
265
254
243
232
221
210
199
188
177
166
155
144
133
122
111
89
100
78
67
56
45
34
23
1
12
0
Industrial equipment have numerous sources of vibration, all of which will be included in the spectrum and waveform.
Lake - Cooling Tower #1 Fan Motor CT1 -M1A Motor Outboard Axial
0.08 0.07
Route Spectrum 02-Jul-04 10:03:14 OVERALL= .1344 V-DG PK = .1341 LOAD = 100.0 RPM = 1757. (29.29 H
0.06 0.05 0.04 0.03 0.02 0.01 0 0
10
20
30 40 50 60 Frequency in Orders
70
1.0 Acceleration in G-s
z
PK Velocity in In/Sec
Actual Spectra & Waveform
80
Route Waveform 02-Jul-04 10:03:14 RMS = .2551 PK(+/-) = .8398/.9374 CRESTF= 3.67
0.5 0 -0.5 -1.0 -1.5 0
30
60
90 120 Time in mSecs
150
180
Signal Acquisition/Processing Transducer Amplitude
Overall Energy
Waveform
Time
FFT Spectrum Amplitude Frequency
FFT = Fast Fourier Transform
Sources of Vibration z
Simplest Rotating Machine – Mass spinning on an axis
Sources of Vibration z
Imbalance – Center of Mass is not the Center of rotation
Heavy Spot
Sources of Vibration z
Misalignment – Two Masses spinning on a coupled axis
Sources of Vibration z
Rolling Element Bearing
Sources of Vibration z
Rolling Element Bearing
Sources of Vibration Fundamental Train (FTF) = S/2 x(1-Bd/Pd x cosθ) Inner Race (BPFI) = Nb/2 x S x (1+Bd/Pd x cosθ) Outer Race (BPFO) = Nb/2 x S x (1-Bd/Pd x cosθ) Roller Pass (BSF)=Pd/2BdxSx[1-(Bd/Pd)2 x (cosθ)2 S = Speed Bd = Roller Diameter Nb = Number of Rollers Pd = Pitch Diameters Θ = Contact Angle
Sources of Vibration z
Flow Related – Vane Pass – Blade Pass
Sources of Vibration z
Gear Vibration – Gearmesh = # Teeth x turning speed – Shaft speeds
Sources of Vibration z
Structural – Looseness – Resonance
Measuring Vibration z
Three common types of sensors that measure the three components of vibration: – Displacement Probes – Velocity Probes – Accelerometers
Measuring Vibration z
z
z
Sensors can be permanently or temporarily mounted Bolted to equipment, connected with adhesive, or magnets Sensors can be connected to portable equipment or continuous monitoring systems.
Example of an Accelerometer on a Pump
Example of a Displacement Probe on a Turbine Bearing
Proximity Probe
Accelerometer
Types of Vibration Data z z z
Monitoring Overall Vibration Parameter Banding, Alarms and Trending Spectral Analysis
Types of data – Overall Vibration 1.2
1
0.8
0.6
0.4
0.2
397
386
375
364
353
342
331
320
309
298
287
276
265
254
243
232
221
210
199
188
177
166
155
144
133
122
89
111
78
100
67
56
45
34
0 1
It includes all vibration in the spectrum or waveform (depending on the type of overall) and is independent of frequency
Spectrum (FFT) 1.4
23
z
Overall Vibration is the sum total of all vibration measured
12
z
Total Vibration 3
2
1
0
-1
-2
-3
Total Vibration
1.2
1
1
0.8
0.8
Amplitude
1.2
0.6
0.6
0.4
0.4
Bearing Defect
Frequency
Overall Vibration 11.7
397
385
373
361
349
337
325
313
301
289
277
265
253
241
229
217
205
193
181
169
157
145
133
121
97
109
85
73
61
49
0 37
0 25
0.2
1
0.2
13
Amplitude
Overall Vibration Levels
1
14 27 40 53 66 79 92 105 118 131 144 157 170 183 196 209 222 235 248 261 274 287 300 313 326 339 352 365 378 391 Frequency
Overall Vibration 12.0
Overall Monitoring Instruments z
Benefits – Easy to use – Gives an empirical indication of overall condition
z
Limitations – Unable to isolate background vibration – Unable to identify sources of vibration – Detection is limited to late stage faults
Band 1
1 2 3 4 5 6 7
397
386
375
364
353
342
331
320
309
298
287
276
265
254
243
232
221
210
199
188
177
166
155
144
133
122
111
100
89
78
67
56
45
34
23
12
Parameter Banding/Alarming Spectrum (FFT)
1.4
1.2
1
0.8
0.6
0.4
0.2
0
Band 1
1 2 3 4 5 6 7
397
386
375
364
353
342
331
320
309
298
287
276
265
254
243
232
221
210
199
188
177
166
155
144
133
122
111
100
89
78
67
Inner Race
Outer Race
Electrical
Misalignment
1
56
45
Imbalance
1.2
34
1.4
23
12
Parameter Banding/Alarming Spectrum (FFT)
0.8
0.6
0.4
0.2
0
Spectral Analysis A2 - Tending Side Brg(Outer Race) TSBRG -R1H ROLL BRG. #1 - HORIZONTAL
PK Velocity in In/Sec
0.024
Route Spectrum 07-Jun-96 12:26:02 OVERALL= .0584 V-DG PK = .0608 LOAD = 100.0 FPM = 10669. (383. RPM)
0.020 0.016 0.012 0.008 0.004 0 0
100
200 300 Frequency in Hz
400
Acceleration in G-s
0.3
500
Route Waveform 07-Jun-96 12:26:02 RMS = .0615 PK(+/-) = .2060/.1977 CRESTF= 3.35
0.2 0.1 0.0 -0.1 -0.2 -0.3 0
200
400
600 Time in mSecs
800
1000
Spectral Analysis A2 - Tending Side Brg(Outer Race) TSBRG -R1H ROLL BRG. #1 - HORIZONTAL
PK Velocity in In/Sec
0.024 C
0.020
C
C
C
Route Spectrum 07-Jun-96 12:26:02 OVERALL= .0584 V-DG PK = .0608 LOAD = 100.0 FPM = 10669. (383. RPM) >TMK 688TD C=BPFO: 65.38
C
0.016 0.012 0.008 0.004 0 0
100
200 300 Frequency in Hz
400
Acceleration in G-s
0.3
500
Route Waveform 07-Jun-96 12:26:02 RMS = .0615 PK(+/-) = .2060/.1977 CRESTF= 3.35
0.2 0.1 0.0 -0.1 -0.2 -0.3 0
200
400
600 Time in mSecs
800
1000
Spectral Analysis z
Benefits – Identify faults – Determine severity
z
Limitations – Time consuming – Requires training and experience
A balance of technology z z
z
z
Baseline all equipment with Spectral Analysis Use parameter banding and trending as a screening tool Only do detailed analysis on equipment with alarms or increasing trends Use overall vibration as a trip setting
CSI 4500 Machinery Health Monitor Technical Details
16 Tach Channels 1x Peak and Phase - PulsePulse-type speed inputs - Frequency divider - Adaptive tach feature - autoauto-locks on speed
32 Sensor monitors
Alerts in less than 100mSec - Accelerometers - Velocity probes - Displacement probes - AC signal - Flux/Dynamic pressure - DC signal - Temperature/Load
Processor / Comm 16 Digital I/O - Input and outputs - OPTOTM relay modules
- Ethernet HUB and NIC - 1 Predictive Processor - 1 Processor feeding live updates - Up to 32 Mb memory - New Local Display
Aux Power +/+/- 24 Vdc (Displacement probes) Unit Input Power 24 Vdc OR
110 / 220 VAC
CSI 4500 Machinery Health Monitor Technical Details z
Uses all three levels of vibration analysis – Gross Scan (Overall) – Parameter banding, trending and alarming – Spectrum and waveform
z
You determine the conditions under which data is collected and how often it is stored.
CSI 4500 Machinery Health Monitor Technical Details z
12, 16, and 32 analog input channels available
CSI 4500 Machinery Health Monitor Technical Details Control Room Online Watch
Plant Control System
Maintenance Engineering AMS Machinery Online Watch Manager
Plant Network
Common Server for MHM Online and LAN Software
MHM Server Dedicated Ethernet (or wireless) provided by customer
Digital I/O to DCS
JBOX JBOX
JBOX
JBOX
Boiler Feed Water Pumps Option 1 Option 2 8 Proximity 5 Accelerometers Probes and one and one tachometer per tachometer per pump pump
Cooling Water Pumps 5 Accelerometers and one Tachometer per pump
JBOX
PDM Group AMS Machinery Manager
4500 Connectivity AMS Asset Portal
Other Control Systems
XML*
Operations
Maintenance AMS Device Manager
AMS Machinery Manager
Ethernet
CSI 4500 Machinery Health Monitor
Critical Machinery
CSI 4500 Machinery Health Monitor Technical Details z
Predicate based data collection Speed
Analog Input
Digital I/O
Predicate Based Data Collection Overall Vibration 1.2 1
Amplitude
0.8 0.6 0.4 0.2 0 1
2
3
4
5
6
7
8
9
10 11 12 13
Time
14 15 16 17 18
Predicate Based Data Collection Overall Vibration w/ RPM 4000
1.2
3500
1
3000 0.8
RPM
2500
0.6
2000 1500
0.4
1000 0.2
500 0
0 1
2
3
4
5
6
7
8
9 10 11 12 13 14 15 16 17 18 Time
RPM Overall
Predicate Based Data Collection Overall Value by Speed 1.2 High Speed Alarm
1
Amplitude
0.8 High speed
0.6 Low Speed Alarm
0.4 0.2 0 1
2
3
4
5
6
7
8
9 10 11 12 13 14 15 16 17 18 Time
Low Speed
Failure Curve Infant Mortality
Expected Life
Probability of Failure
Predictive System
End of Life Protection System
Failure
sion s e r og lt Pr u a F
Time
Machinery Applications in a Typical Plant Total # Machines 2,500 Typical Industrial Process Plant
Turbines Generators Compressors
Motors Pumps Fans Gears
~125 Machines
~625 Machines
5% Critical
25% Essential
Online Monitoring
CSI 4500 Monitor
Loss of machine means > 40% lost plant capacity
CSI 9210 Transmitter
Automated Data Collection Periodic Data Collection
~750 Machines
~500 Machines ~500 Machines
30% Important
20% Secondary 20% Non-Essential
Portable Portable
CSI 2130 Analyzer
Run to Fail
Installed Systems & Applications Summary of Customers by Industry
Questions??
