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WELCOME TO

2014 - MRO Technical Conference and Workshops. WELCOME TO. Utilizing Predictive Technologies to Provide Early Warning of Degrading Machinery Health. AGENDA -Why Predictive Monitoring? -Vibration What is it? Sensor types and applications Stress wave detection with Case Study

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WELCOME TO

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  1. 2014 - MRO Technical Conference and Workshops WELCOME TO

  2. Utilizing Predictive Technologies to Provide Early Warning of Degrading Machinery Health • AGENDA • -Why Predictive Monitoring? • -Vibration • What is it? • Sensor types and applications • Stress wave detection with Case Study • -Oil Analysis • Functions of a Lubricant • Lubricant Degradation and Contamination • Wear Debris Analsis • -Infrared • Why use IR technology? • Case study examples

  3. Utilizing Predictive Technologies to Provide Early Warning of Degrading Machinery Health Oil Vibration Infrared

  4. Strategies to Achieve Reliability Reactive Maintenance -Run to failure (costly and ineffective) Preventive Maintenance -Based on runtime (whether it needs it or not) Predictive Maintenance -Based on periodic readings (monthly, quarterly, or longer) Proactive Maintenance -Taking corrective action to mitigate failure

  5. Probability to Failure Curve Prediction Protection 100% Equipment Health Downtime Failure 0% Time

  6. What is Vibration?

  7. ICP vs 4-20mA Signal Spectrum 4-20mA Waveform Trending Severity Levels Identify Faults

  8. Trending - Band Alarming

  9. Faults found with Vibration Monitoring • Unbalance • Misalignment • Looseness • REB faults • Gear faults • Oil whirl • Oil whip • Resonance • Cavitation • Broken rotor bars

  10. ROTOR How are measurements taken? Piezoelectric Accelerometers or Velocity Sensors mounted in horizontal, vertical or axial planes pick up highly directional vibration signal.

  11. Rotor to case ratio is not adequate ROTOR Oil wedge attenuates vibration transmitted through case How are measurements taken? Require a different approach for sleeve bearing applications due to lack of sensitivity caused by oil wedge.

  12. Displacement probes are the preferred sensor for sleeve bearings. • X-Y orientation provides: • Shaft orbit • Shaft centerline ROTOR Probe directly detects rotor vibration Eddy Current Sensors

  13. Eddy Current Sensors Probe (Sensor) To monitoring system Extension Cable Converter Field Wiring 3-Conductor, Shielded Converter

  14. Detecting Stress Waves • Stress waves are generated from faults that result in impacting, friction, fatiguing, etc. • Bearing defects • Lubrication faults • Rubs • Cavitation • Cracks • Gear looseness • Difficult to separate stress waves from regular vibration data due to the short duration (µs → ms), high frequency nature (2 – 30 kHz) of these waves. Two detection techniques : Demodulation and PeakVue

  15. Signal Processing Overview Represent amplitude in digital format Time to frequency conversion Raw time waveform Ensure continuous and periodic sampled waveform Helps improve data by reducing noisy signals High Pass filter applied here for both techniques

  16. PeakVue Case Study -Outer Race Defect in Gearbox Bearing

  17. PeakVue Case Study Regular vibration data shows little indication of any issue

  18. PeakVue Case Study Spectrum helps determine problem frequencies (i.e. ball spin freq) Waveform used to assess severity of faults. Factors may include machine type, speed, sensor location, etc. PeakVue data shows severe indication (35 G’s) of BPFO

  19. PeakVue Case Study Significant spalling over an area of 5” x 5” on the outer race of the defective bearing

  20. PeakVue Case Study PeakVue data after bearing replacement

  21. Oil Analysis • Billions of dollars spent annually replacing machinery components that have worn prematurely due to improper lubricant • Goal is to increase uptime and life of critical equipment and schedule maintenance before asset failure

  22. Functions of a Lubricant Friction control --- Separates moving surfaces Wear control --- Reduces abrasive wear Corrosion control --- Protects surfaces from corrosive substance Temp control --- Absorbs and transfer heat Contamination control --- Transport particles and other contaminants to filters/separators Power transmission --- In hydraulics, transmits force and motion

  23. On-site minilab No delay Test incoming lubricants Ownership and control Find and fix contamination Off-site oil lab No capitalinvestment Expertise Extensive instrumentation Less expensive for < 30 samples per month Oil analysis choices

  24. Taking Oil Samples Sampling From Pipes: • Turbulent flow to keep particles entrained in the oil • The oil is hot • Take sample from center of pipe if possible • Flush line thoroughly before sampling Sampling From Tanks: • Take from center of tank and well clear of bottom or sides Label sample immediately. Remember to always sample from the same point and when the machine is operating. Sampling Frequency considerations: • Criticality (from a safey, environment, or cost perspective) • Operating conditions (load, speed) • Failure history

  25. Oil Viscosity Quickly and easily allows you to determine if wrong grade oil is present. Can be an indicator of oxidation or nitration, increased contamination or an increase of insolubles.

  26. Oil Degradation/Chemistry Degradation of lubricant caused primarily by the breakdown of chemical components in the oil which result in the formation of acidic by-products. This leads to corrosion and the formation of varnish and sludge which can quickly clog oil filters. TAN/TBN – Total Acid/Base Number (mgKOH or equivalent to neutralize 1g of sample) TBN used as an indication of alkaline additive reserves in diesel engines

  27. Wear Debris Analysis • Wear debris analysis is the “referee” • -Root cause • -Severity • Analyze sample • -Concentration, size, color texture, shape, composition classification, & severity. • -Measure with mouse • Capture images • -Annotate images • Report ISO code

  28. Infrared for Condition Monitoring Great supplementary technology to both vibration and oil analysis. Relatively inexpensive and simple to use. Images can be taken from a safe distance.

  29. IR Camera Considerations • What is the target’s area of interest (spot size)? • What is the distance to the target? • What is the targets maximum temperature?

  30. IR Case Study 1 Motor testing over time • Left side 72 F – no problem, • Right side (1 year later > 90 F) A motor operating at 10 degrees over design can cut the life of the motor in half

  31. IR Case Study 2 Misalignment problem causing excessive heat at inboard motor bearing

  32. Thank You

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