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oct/nov 11
ViB
vibration
This is the final part of the series on dealing with rolling element bearing defects. In previous articles, we looked at how vibration analysis can be used to detect a range of faults conditions, including lubrication problems; wear, spalls, cracks and other defects; and problems that relate to poor installation practices. In this article, we will discuss how the vibration analyst (and others within the maintenance and operations group) can minimize the number and severity of bearing faults. This is arguably the most important of the four articles.
Part 4
f you asked most people whether vibration analysis improved reliability, they would answer, Yes. But I would disagree.
The same is true with your rotating machinery. In most plants, the vibration analysts are the red light on the dashboard. They take readings, see that there is a problem, then wave their hands to say, you need to take action because the bearing is about to fail. If the vibration analyst does a good job, then there will be more time between the red light coming on and the machine failing. As a result, the maintenance department will have more time to deal with the repair: order the parts, find the most convenient time to shut the machine down, operate the machine through a critical period, operate the machine more safely, etc. But there is much more that the vibration analyst and the maintenance and operations departments can do. The goal has to be to increase the life of the bearing thats what makes a machine more reliable.
How would you feel if your car failed as often as most rotating machines?
If you found that every three months your car engine failed and thus you often found yourself stranded on the side of the road, then you would correctly say that your car is unreliable. But if the mechanics added a red light to your cars dashboard that warned of imminent failure so you could avoid being stranded on the side of the road, you would feel like that was a step in the right direction. But if the red light comes on every three months, you would still feel as if your car is unreliable. You would be
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Operation If a machine is operated correctly, there are less stresses on the components (bearings, shaft, seals, etc.). It is primarily up to the operators to ensure a machine is operating correctly, but the vibration analyst and other condition monitoring technicians can perform tests to verify that it is operating properly. Maintenance Similarly, if a machine runs more smoothly, there will be less stress on the components and it will be more reliable. The maintenance department has an important role to play. The bearings and gears should be lubricated correctly. In addition, the shafts should be precision aligned; there should be no soft foot; the rotating elements should be correctly balanced; there should be minimal resonance; the bearings should be installed correctly; and so on. If the maintenance department gets all of the fundamental maintenance issues right, then the machine will be far more reliable. As a result, the vibration analyst should see very few fault conditions develop. So what is the role of the vibration analyst? The vibration analyst may be involved in precision alignment and should be involved with field balancing. The vibration analyst can certainly take the required readings to check for misalignment, soft foot, lubrication problems, bearing installation problems, unbalance, looseness, resonance, flow problems, and so on. If these tests are performed correctly and the conditions are corrected quickly, the machine will provide many years of reliable operation. Yes, it will take cooperation between maintenance and the condition monitoring group, and it will require the vibration analyst to master all the necessary skills, but it is definitely worth it. Continuous improvement Even with the best intentions, there will still be failures. The important factor is to learn from failure. Root cause failure analysis can be used to determine why a machine failed but it is important to go back and make changes so that the failure does not occur again. A vibration analyst can play a very important role. The vibration data can hold the clue as to why a machine failed. It may be that a bearing failed, for example, but careful examination of the data may identify a condition (unbalance, misalignment, resonance, etc.) that led to the failure. When the bearing is removed from the machine, it should be examined to determine why the failure occurred. In the example in Figure 1, the pump was in standby mode for long periods and experiencing vibration from a second unit, thus false brinelling occurred.
ability adds to the bottom line of the balance sheet. While there will be an initial investment (training, instrumentation, design modifications, etc.), the improvements in production, quality and energy efficiency, and the reduction in maintenance costs (parts and labor) and safety incidences will result in a very fast return on investment.
Figure 2 - Laser alignment systems are great, but without adequate training, they will be misused
Conclusion
A good vibration analyst will detect a bearing defect before it fails. A better analyst will detect the defect earlier and communicate the status so action can be taken to minimize the cost of repair. But the best vibration analysts do everything possible to reduce the likelihood that the bearing will ever develop a defect in the first place.
Figure 1 - This bearing has failed due to false brinelling. Image adapted from FAG Publ. No. WL 82 102/2 ED
Jason Tranter is the founder of Mobius Institute and author of iLearnVibration and other training materials and products. Jason has been involved in vibration analysis in the USA and his native Australia since 1984. Before starting Mobius Institute, Jason was involved in vibration consulting and the development of vibration monitoring systems. www.mobiusinstitute.com
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