CSI 4500 Machinery Health Monitor Overview

Jon Hall Novaspect, Inc.

Failure Curve
Infant Mortality Expected Life End of Life Protection System Probability of Failure

Time

Failure Curve
Infant Mortality Expected Life End of Life Protection System

Predictive System
Probability of Failure

Failure

ion ress Prog ault 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

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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

Critical Equipment Hard to Access
Distance Safety

Man Power Repeatability

Protection System
Normally based on overall vibration levels Designed to prevent additional damage after failure REACTIVE

Predictive System
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

~125 Machines

5% Critical

Online Monitoring
Loss of machine means > 40% lost plant capacity
Automated Data Collection Periodic Data Collection

CSI 4500 Monitor

Motors Pumps Fans Gears

~625 Machines

25% Essential

CSI 9210 Transmitter

~750 Machines

30% Important

Portable Portable
CSI 2130 Analyzer

~500 Machines ~500 Machines

20% Secondary 20% Non-Essential

Run to Fail

Introduction to vibration
Vibration The motion of a body about a reference point At its simplest, vibration is displayed as displacement over time, in Mils.

Simple Vibration at 60 Hz - Displacement

1.5

Period
1

0.5

Displacement 60Hz

-0.5

-1

Amplitude
-1.5

Freq= 1/Period

Velocity at 180 Hz
1.5 1

0.5

Displacement 180Hz Velocity 180 Hz

-0.5

-1

-1.5

Acceleration Rate of Change of Velocity

1.5

0.5

Displacement 60Hz 0 Velocity 60 Hz Acceleration 60Hz

-0.5

-1

-1.5

The units
Displacement accentuates the low frequencies - Mils Acceleration accentuates the higher frequencies (gs) 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

-0.5

-1

-1.5

Turning Speed Time Waveform

Types of Data Time Waveform

1.5 1

0.5

Turning Speed 2x TS

-0.5

-1

-1.5

Add twice turning speed vibration

Types of Data Time Waveform

1.5 1

0.5

Turning Speed 0 2x TS 7x TS

-0.5

-1

-1.5

Add blade pass vibration

Types of Data Time Waveform

1.5 1

0.5

Turning Speed 0 2x TS 7x TS Brg

-0.5

-1

-1.5

Add Bearing Vibration

Types of Data Time Waveform

Total Vibration 3

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
RPM

Frequency
Hz ( / 60) Orders (Motor Speed)

Motor Belts Fan Shaft Fan Blades Roller Brgs

1. BPFI 2. BPFO 3. BSF 4. Cage

1800 720 900 4 x 900

10,638 7,362 4,752 736

30 12 15 4 x 15
177.3 122.7 79.2 12.3

1.0 0.4 0.5 4 x 0.5

5.91 4.09 2.64 0.409

Structure

420

0.23

Collection of Data Data What would I expect to see?

Component
RPM

Frequency
Hz ( / 60) Orders (Motor Speed)

Motor Belts Fan Shaft Fan Blades Roller Brgs

1. BPFI 2. BPFO 3. BSF 4. Cage

1800 720 900 4 x 900

10,638 7,362 4,752 736

30 12 15 4 x 15
177.3 122.7 79.2 12.3

1.0 0.4 0.5 4 x 0.5

5.91 4.09 2.64 0.409

Structure

420

0.23

A Typical Waveform

Need Spectrum Analyzer for diagnostics, not just Overall vibration meter

Types of Data - Spectrum

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

-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

0.5

FFT

-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

1.2

Twice Turning Speed Turning Speed

0.8

0.6

Blade Pass
0.4

Bearing Frequency
0.2

0 1 12 23 34 45 56 67 78 89 100 111 122 133 144 155 166 177 188 199 210 221 232 243 254 265 276 287 298 309 320 331 342 353 364 375 386 397

Actual Spectra & Waveform

PK Velocity in In/Sec

Industrial equipment have numerous sources of vibration, all of which will be included in the spectrum and waveform.

0.08 0.07 0.06 0.05 0.04 0.03 0.02 0.01 0 0 1.0 10

Lake - Cooling Tower #1 Fan Motor CT1 -M1A Motor Outboard Axial Route Spectrum 02-Jul-04 10:03:14 OVERALL= .1344 V-DG PK = .1341 LOAD = 100.0 RPM = 1757. (29.29 H

20

30 40 50 60 Frequency in Orders

70

80

Acceleration in G-s

0.5 0 -0.5 -1.0 -1.5 0 30 60 90 120 Time in mSecs 150

Route Waveform 02-Jul-04 10:03:14 RMS = .2551 PK(+/-) = .8398/.9374 CRESTF= 3.67

180

Signal Acquisition/Processing
Transducer Amplitude Amplitude Frequency Waveform

Overall Energy

Time

FFT
Spectrum

FFT = Fast Fourier Transform

Sources of Vibration
Simplest Rotating Machine
Mass spinning on an axis

Sources of Vibration
Imbalance
Center of Mass is not the Center of rotation

Heavy Spot

Sources of Vibration
Misalignment
Two Masses spinning on a coupled axis

Sources of Vibration
Rolling Element Bearing

Sources of Vibration
Rolling Element Bearing

Sources of Vibration
Fundamental Train (FTF) = S/2 x(1-Bd/Pd x cos) Inner Race (BPFI) = Nb/2 x S x (1+Bd/Pd x cos) Outer Race (BPFO) = Nb/2 x S x (1-Bd/Pd x cos) Roller Pass (BSF)=Pd/2BdxSx[1-(Bd/Pd)2 x (cos)2 S = Speed Bd = Roller Diameter Nb = Number of Rollers Pd = Pitch Diameters = Contact Angle

Sources of Vibration
Flow Related
Vane Pass Blade Pass

Sources of Vibration
Gear Vibration
Gearmesh = # Teeth x turning speed Shaft speeds

Sources of Vibration
Structural
Looseness Resonance

Measuring Vibration
Three common types of sensors that measure the three components of vibration:
Displacement Probes Velocity Probes Accelerometers

Measuring Vibration
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

Monitoring Overall Vibration Parameter Banding, Alarms and Trending Spectral Analysis

Types of data Overall Vibration

Overall Vibration is the sum total of all vibration measured It includes all vibration in the spectrum or waveform (depending on the type of overall) and is independent of frequency
Spectrum (FFT)
1.4 1.2 1

0.8

0.6

0.4

0.2

0 1 12 23 34 45 56 67 78 89 100 111 122 133 144 155 166 177 188 199 210 221 232 243 254 265 276 287 298 309 320 331 342 353 364 375 386 397

Total Vibration 3

Total Vibration

-1

-2

-3

Overall Vibration Levels

1.2 1.2

0.8

0.8

Amplitude

Amplitude

0.6

0.6

0.4

0.4

Bearing Defect
0.2 0.2 0 1 13 25 37 49 61 73 85 97 109 121 133 145 157 169 181 193 205 217 229 241 253 265 277 289 301 313 325 337 349 361 373 385 397 Frequency 0 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 11.7

Overall Vibration 12.0

Overall Monitoring Instruments

Benefits
Easy to use Gives an empirical indication of overall condition

Limitations
Unable to isolate background vibration Unable to identify sources of vibration Detection is limited to late stage faults

Parameter Banding/Alarming

Band
0.2 0.4 0.6 0.8 1.2 1.4 0 1 12 23 34 45 56 67 78 89 100 111 122 133 144 155 166 177 188 199 1

1 2 3 4 5
210 221 232 243 254 265 276 287 298 309 320 331 342

Spectrum (FFT)

6 7

353 364 375 386 397

Parameter Banding/Alarming

Band
0.2 0.4 0.6 0.8 1.2 1.4 0 1 12 23 34 45 56 67 78 89 100 111 122 133 144 155 166 177 188 199 210 221 232 243 254 265 276 287 298 309 320 331 342 1

1 2 3 4 5 6 7
353 364 375 386 397

Imbalance Misalignment Electrical Outer Race

Spectrum (FFT)

Inner Race

Spectral Analysis
0.024 PK Velocity in In/Sec 0.020 0.016 0.012 0.008 0.004 0 0 0.3 Acceleration in G-s 0.2 0.1 0.0 -0.1 -0.2 -0.3 0 200 400 600 Time in mSecs 800 1000 100 200 300 Frequency in Hz 400 500 A2 - Tending Side Brg(Outer Race) TSBRG -R1H ROLL BRG. #1 - HORIZONTAL Route Spectrum 07-Jun-96 12:26:02 OVERALL= .0584 V-DG PK = .0608 LOAD = 100.0 FPM = 10669. (383. RPM)

Route Waveform 07-Jun-96 12:26:02 RMS = .0615 PK(+/-) = .2060/.1977 CRESTF= 3.35

Spectral Analysis
0.024 PK Velocity in In/Sec 0.020 0.016 0.012 0.008 0.004 0 0 0.3 Acceleration in G-s 0.2 0.1 0.0 -0.1 -0.2 -0.3 0 200 400 600 Time in mSecs 800 1000 100 200 300 Frequency in Hz 400 500 C A2 - Tending Side Brg(Outer Race) TSBRG -R1H ROLL BRG. #1 - HORIZONTAL C 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

Route Waveform 07-Jun-96 12:26:02 RMS = .0615 PK(+/-) = .2060/.1977 CRESTF= 3.35

Spectral Analysis
Benefits
Identify faults Determine severity

Limitations
Time consuming Requires training and experience

A balance of technology
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

- Pulse-type speed inputs Pulse- Frequency divider - Adaptive tach feature - auto-locks on speed auto-

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

32 Sensor monitors

Alerts in less than 100mSec

- Accelerometers - Velocity probes - Displacement probes - AC signal - Flux/Dynamic pressure - DC signal - Temperature/Load

Aux Power +/- 24 Vdc +/(Displacement probes) Unit Input Power 24 Vdc
OR

110 / 220 VAC

CSI 4500 Machinery Health Monitor

Technical Details

Uses all three levels of vibration analysis

Gross Scan (Overall) Parameter banding, trending and alarming Spectrum and waveform

You determine the conditions under which data is collected and how often it is stored.

CSI 4500 Machinery Health Monitor

Technical Details

12, 16, and 32 analog input channels available

CSI 4500 Machinery Health Monitor

Technical Details
Plant Control System Control Room Online Watch Maintenance Engineering AMS Machinery Online Watch Manager PDM Group AMS Machinery 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

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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

4500 Connectivity
AMS Asset Portal

Other Control Systems Operations

AMS Device Manager

XML*

Maintenance
AMS Machinery Manager

Ethernet

CSI 4500 Machinery Health Monitor

Critical Machinery

CSI 4500 Machinery Health Monitor

Technical Details

Predicate based data collection

Speed Digital I/O

Analog Input

Predicate Based Data Collection

Overall Vibration
1.2 1 0.8 Amplitude 0.6 0.4 0.2 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Time

Predicate Based Data Collection

Overall Vibration w/ RPM
4000 3500 3000 2500 RPM 2000 1500 1000 500 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Time 0.2 0 0.8 0.6 0.4 RPM Overall 1.2 1

Predicate Based Data Collection

Overall Value by Speed
1.2
High Speed Alarm

1 0.8 Amplitude 0.6

Low Speed Alarm

High speed Low Speed

0.4 0.2 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Time

Failure Curve
Infant Mortality Expected Life End of Life Protection System

Predictive System
Probability of Failure

Failure

ion ress Prog ault F

Time

Machinery Applications in a Typical Plant

Total # Machines 2,500
Typical Industrial Process Plant

Turbines Generators Compressors

~125 Machines

5% Critical

Online Monitoring
Loss of machine means > 40% lost plant capacity
Automated Data Collection Periodic Data Collection

CSI 4500 Monitor

Motors Pumps Fans Gears

~625 Machines

25% Essential

CSI 9210 Transmitter

~750 Machines

30% Important

Portable Portable
CSI 2130 Analyzer

~500 Machines ~500 Machines

20% Secondary 20% Non-Essential

Run to Fail

Installed Systems & Applications

Summary of Customers by Industry

Questions??