FDS - A Revolution in Fluid Film Bearing Monitoring

Revolution in Fluid Film Bearing Monitoring
Insight Force Detection Sensor
© PRUFTECHNIK Inc. Author: Dries Van Loon Slide 1

Monitoring Techniques
 Proximity Probes
Pros
 Actual shaft position in housing (DC/gap)
 Dynamic shaft movement (AC/orbit)
 Easy to evaluate vs bearing clearance
 Diagnostic possible
Cons
 Slow roll compensation
 Cost (hardware >2k$)
 Retrofit installation, drill-tap ( $ >>> Hardware)

 Temperature
 Bearing housing or Babbitt temperature
 Lubricant temperature
 Pros
 Easy to install
 Better than no indication
 Cons
 No diagnostic
 Thermal Lag
 Alarm too late (temperature after damage)

 Case Mounted Vibration

 Accelerometer or Velometer on casing housing
 Casing vibration combined with relative shaft vibration (full picture)
 Pros
 Easy to install or collect with route data collection
 Trending and some diagnostics
 Together with prox. probe get full picture
 Better than nothing
 Cons
 Transmission path not linear
 Force from shaft to measurement location
 Many harmonics hard to make diagnostic conclusions

 Not at all??
 Pros
 Cheap
 Cons
 Very Expensive

 Conclusion
 Proper configured X-Y proximity probes currently best
 Expensive for retrofit installation (Hardware + Installation + Shutdown)
 Other monitoring techniques not sufficient individually
 Need for innovation

 Low (retrofit) installation cost
 Trending (protection) and diagnostic of fluid film bearings
 New technology
 Insight Force Detection Sensor

Insight FDS
Force Detection Sensor

Insight FDS
 Principle
Use dynamic strain sensor on the housing of a fluid film bearing,

installed in the load zone of the bearing (pressure wedge), to
measuring indirectly the bearing forces and monitor the condition of
the machine. (US Patent nr. US9841329B2)
https://patents.google.com/patent/US9841329B2/en

Insight FDS
 Kinematics
 Even though bearing acceleration is low, large forces are still transmitted resulting in
significant strain (με)
 Trends and alarms are direct measures of potential damage

Insight FDS
 Technology
 Piezoelectric sensing element
 Titanium bottom plate (engineered thickness)
 IEPE power (same as ICP sensor)
 Unidirectional
 Technical Specs (PTA-FDS102-VOY)

 Dimensions: .425” x .6” x .180”
 Sensitivity: 50 mV/με (± 20%)
 Measurement Range: +-100 με
 Frequency Range: 0.5Hz-10kHz
 Temperature Range: -22°F to 250°F
 Integral cable with 10-32 UNF Connector
 Sensor and cable submersible (oil)
 Class 1 Div. 2

Insight FDS
 Technology
 Piezoelectric sensing element
 Titanium bottom plate (engineered thickness)
 IEPE power (same as ICP sensor)
 Unidirectional
 Technical Specs (PTA-FDS101-VOY)

 Dimensions: 1.57” x .67” x .58”
 Sensitivity: 40 mV/με (± 20%)
 Measurement Range: +-100 με
 Frequency Range: 0.01Hz-10kHz
 Temperature Range: -22°F to 250°F
 10-32 UNF Connector

Insight FDS
 Pressure Wedge
 Predictable for all bearing types
 Ideal location for FDS sensor install (BDC or 430 & 730)

Insight FDS
 Install (<1h)
 Define pressure wedge location (Load?)
 Remove loose paint, oil and solvents
 ± Flat surface (not interested in static strain)
 Glue sensor to bearing housing
 Magnetic installation tool
 Measure

Insight FDS
 Measure (as ICP sensor)

 Setup sensor (50 mV/με)
 Trend overall strain for alarming
 Spectra and Time Waveform for detailed analysis
 Trending in DCS

Insight FDS

 Handheld data collector (does not have to be Pruftechnik device)

Insight FDS

 Continuous Monitoring (does not have to be Pruftechnik device)

Insight FDS
 Alarming
 Evolving process (just like vibration)
 Trending and statistical alarms (just like vibration)
 Critical alarm level can be calculated (application specific)
 Load and Speed
 Babbitt material properties (elastic limits)
 Young’s Modulus
 Alarm percentages (15-25%) of calculated max due to mounting location

Insight FDS
 Pricing
 PTA-FDS102-VOY - $990 per sensor
 PTA-FDS101-VOY - $750 per sensor
 PTA-MT-MK04-VOY - Installation Kit (for FDS102) - $100

 PTA-MT-MK03-VOY - Installation Kit (for FDS101) - $80
PTA.SCA-1032F-BNCM.VO - Adapter (10-32F to BNCM, 3ft) - 50.00 $
 Installation cost <<< compared to retrofit prox. Probes (shutdown time)

 Monitoring cost
 Overall mA to DCS
 Route data collection
 Continuous online monitoring

Example Data

Data VIBGUARD
 Comparing data
 High Speed compressor
 Prox., Accel., FDS
 VIBGUARD portable (Cloud Connectivity)
 OMNITREND Center Cloud Server
 Online View (Live data and condition visualization)

Data VIBGUARD
- Overall Pk-Pk
SPEED
FDS
ACCEL
PROX

Data VIBGUARD
- Spectra
FDS
ACCEL
PROX

Data VIBGUARD
- Spectra - detail
FDS
ACCEL
PROX

Data VIBGUARD
- Timewave form - detail
FDS
ACCEL
PROX

Lab Data
 Lab Rotor Setup

 100 psi bearing pressure
 0 – 1800 RPM
 Critical Speed at 1320 RPM
 Internally designed hydrodynamic bearings
 Thick Film Lubrication at 115 RPM
 ISO VG 35 Equivalent Oil
 IB Bearing 0.00275” Clearance
 OB Bearing 0.004” Clearance
 2”Diameter Shaft, L/D = 0.375
 Thick Babbitt 0.0625”
 Sensors:
 Insight FDS
 Proximity Probes
 RTD’s

Lab Data
 Amplitude/pattern comparison
 Velocity  Dynamic Strain
v op [inch/ s] R otor Kit N o Malf unc tio ns Abov e Critic al\ OB Ac c el N\ 1099 ACC FFT on FD S Rotor 2/ 28/ 2019 3:00:01 PM strain [ue] R otor Kit N o Malf unc tio ns Abov e Critic al\ OB Strain BDC\ 1102 Strain spec trum on Lab R otor 2/ 28/ 2019 3:05:28 PM
0.0080 0.90
0.0075 0.85
(1515.00 / 0.77)
RPM : 1800 (30.00Hz) 0.80 RPM : 1800 (30.00Hz)
0.0070
M(x) : 1515.00 cpm (0.84 Orders) M M(x) : 1515.00 cpm (0.84 Orders)
M(y) : 0.00566 inch/ s M(y) : 0.77 ue
0.75
0.0065
0.70
0.0060 (1515.00 / 0.00566)
M 0.65
0.0055
0.60
0.0050
0.55
0.0045 0.50
0.0040 0.45
0.0035 0.40
0.35 (1245.00 / 0.30)

0.0030
0.30
0.0025
0.25
0.0020 (1245.00 / 0.00162)
0.20
0.0015
0.15
0.0010
0.10
0.0005 0.05
0.0000 0.00
0 2000 4000 6000 8000 10000 12000 14000 16000 18000 20000 22000 24000 0 2000 4000 6000 8000 10000 12000 14000 16000 18000 20000 22000 24000
f [cpm] f [cpm]

Lab Data
 Acceleration  Dynamic Strain
a [g] R otor Kit N o Malf unc tions Abov e Crit ic al\ OB Ac c el N \ 1101 Ac c T W F FDS Lab 2/ 28/ 2019 2:59:44 PM strain [ue] R otor Ki t N o Malf unc tio ns Ab ov e Cri tic al\ OB St ra in BD C\ 1103 Strain W av eform on Lab R ot or 2/ 28/ 2019 3:05:51 PM
2.0
0.24
1.8
0.22
1.6
0.20
RPM : 1800 (30.00Hz) RPM : 1800 (30.00Hz)
0.18 M(x) : 57.29 ms 1.4
M(y) : 0.11360 g
0.16 1.2
0.14 1.0
0.12 M
0.8
0.10
0.6
0.08
0.4
0.06
0.2
0.04
0.0
0.02
-0.2
0.00
-0.02 -0.4
-0.04 -0.6
-0.06 -0.8
-0.08 -1.0
-0.10
-1.2
-0.12
-1.4
-0.14
-1.6
-0.16
-1.8
-0.18
-2.0
-0.20
-0.22 -2.2
-0.24 -2.4
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250
t [ms] t [ms]

Lab Data
 Proximity Displacement  Dynamic Strain
s pp [mils] R otor Kit No Malf unc tio ns Abov e Crit ic al\ OB Prox S\ 1098 Dis p FFT on FD S Rotor 2/ 28/ 2019 3:03:03 PM strain [ue] R otor Kit N o Malf unc tio ns Abov e Critic al\ OB Strain BDC\ 1102 Strain spec trum on Lab R otor 2/ 28/ 2019 3:05:28 PM
0.90 0.90
0.85 0.85
(1515.00 / 0.76715) (1515.00 / 0.77)

0.80 RPM : 1800 (30.00Hz) 0.80 RPM : 1800 (30.00Hz)
M M(x) : 1515.00 cpm (0.84 Orders) M M(x) : 1515.00 cpm (0.84 Orders)
0.75 M(y) : 0.76715 mils 0.75 M(y) : 0.77 ue
0.70 0.70
0.65 0.65
0.60 0.60
0.55 0.55
0.50 0.50
0.45 0.45
0.40 0.40
0.35 0.35 (1245.00 / 0.30)
0.30 0.30
0.25 0.25
0.20 0.20
(1237.50 / 0.13504)
0.15 0.15
0.10 0.10
0.05 0.05
0.00 0.00
0 2000 4000 6000 8000 10000 12000 14000 16000 18000 20000 22000 24000 0 2000 4000 6000 8000 10000 12000 14000 16000 18000 20000 22000 24000
f [cpm] f [cpm]

Lab Data
 Proximity Displacement  Dynamic Strain
s [mils] R ot or Kit N o Malfunc tions Abov e Crit ic al\ OB Pro x S\ 1100 D isp T W F FDS R otor 2/ 28/ 2019 3:03: 16 PM strain [ue] R otor Ki t N o Malf unc tio ns Ab ov e Cri tic al\ OB St ra in BD C\ 1103 Strain W av eform on Lab R ot or 2/ 28/ 2019 3:05:51 PM
1.5 2.0
1.4
1.8
1.3
1.6
1.2
RPM : 1800 (30.00Hz) RPM : 1800 (30.00Hz)
1.1 1.4
1.0
1.2
0.9
1.0
0.8
0.7 0.8
0.6
0.6
0.5
0.4
0.4
0.3 0.2
0.2
0.0
0.1
-0.2
0.0
-0.1 -0.4
-0.2
-0.6
-0.3
-0.8
-0.4
-0.5 -1.0
-0.6
-1.2
-0.7
-1.4
-0.8
-0.9 -1.6
-1.0
-1.8
-1.1
-2.0
-1.2
-1.3 -2.2
-1.4
-2.4
-1.5
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250
t [ms] t [ms]

Lab Data
 Coast Down – Bode Plot
 Critical Speed
 Phase shift
με[g] R otor Kit No Malfunc tions At Resonanc e\ N ew Measurement Loc ation\ lab strain c d mag A 3/ 18/ 2019 9:22:06 AM
a op
2.6
M
2.4
2.2
2.0
1.8
1.6
1.4
1.2
1.0
0.8
0.6
0.4
0.2
0.0
600 650 700 750 800 850 900 950 1000 1050 1100 1150 1200 1250 1300 1350 1400 1450 1500 1550 1600 1650 1700 1750 1800 1850 1900 1950
Speed [RPM]
Phase [°]
270
240
210
180
150
120
90
60
30
0
330
300
270
240
600 650 700 750 800 850 900 950 1000 1050 1100 1150 1200 1250 1300 1350 1400 1450 1500 1550 1600 1650 1700 1750 1800 1850 1900 1950
Speed [RPM]

Lab Data
 Coast Down – FFT Waterfall
 1x harmonic – resonance
 Oil Whip
με[g] Rotor Kit No Malfunc tions At Resonanc e\ New Measurement Loc ation\ lab strain c d fft A 3/ 18/ 2019 9:09:05 AM
a op
RPM : 1970 (32.84Hz)

M(x) : 1320.00 cpm (0.67 Orders)
M(y) : 0.80777 g
2.4 1999
1939
2.2 1879
2.0 1821
1764
1.8 1709
1654
1.6
1601
1.4 1548
1497
1.2 1447
1398
1.0
1348
0.8 1300
1253
0.6 1208
0.4 1163
1119
0.2 1076
1034
0.0
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000
f [cpm]

Lab Data
 Unbalance
 Calculated to ISO G8.4 Unbalance
 Applied Evenly to all Four Disks
 Spinning at 70% of 1st Critical
 Remains a Rigid Rotor

Lab Data
 Unbalance
Velocity Data – 1x = 0.0128 ips
v op [inch/ s] Rotor Kit Unbalanc e Belo w Crit ic al\ OB Ac c el N\ 1099 ACC FFT on FD S Rotor 3/ 5/ 2019 3: 09: 30 PM
0.016
0.015
RPM : 1800 (30.00Hz)

0.014
M(x) : 1057.50 cpm (0.59 Orders)
M(y) : 0.01289 inch/ s
M
0.013
0.012
0.011
0.010
0.009
0.008
0.007
0.006
0.005
0.004
0.003
0.002
0.001
0.000
0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000 13000 14000 15000 16000 17000 18000 19000 20000 21000 22000 23000 24000
f [cpm]
Insight FDS Data – 1x = 1.46με

strain [ue] Rot or Kit Unbalanc e Belo w Crit ic al\ OB St ra in BDC\ 1102 Strain sp ec t ru m on Lab Rot or 3/ 5/ 2019 3:16:52 PM
1.8
1.7
1.6 RPM : 1800 (30.00Hz)

M(x) : 1065.00 cpm (0.59 Orders)
1.5 M(y) : 1.46 ue
M
1.4
1.3
1.2
1.1
1.0
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0.0
0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000 13000 14000 15000 16000 17000 18000 19000 20000 21000 22000 23000 24000
f [cpm]

Lab Data
 Unbalance
Proximity Displacement - 1x 1.31mils
s pp [mils] Rot or Kit Unbalanc e Below Crit ic al\ OB Prox N\ 1098 Disp FFT on FDS Rotor 3/ 5/ 2019 3:06: 52 PM
1.6
1.5
RPM : 1800 (30.00Hz)

1.4
M(x) : 1057.50 cpm (0.59 Orders)
M M(y) : 1.31404 mils
1.3
1.2
1.1
1.0
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0.0
0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000 13000 14000 15000 16000 17000 18000 19000 20000 21000 22000 23000 24000
f [cpm]
Insight FDS Data – 1x = 1.46με

strain [ue] Rot or Kit Unbalanc e Belo w Crit ic al\ OB St ra in BDC\ 1102 Strain sp ec t ru m on Lab Rot or 3/ 5/ 2019 3:16:52 PM
1.8
1.7
1.6 RPM : 1800 (30.00Hz)

M(x) : 1065.00 cpm (0.59 Orders)
1.5 M(y) : 1.46 ue
M
1.4
1.3
1.2
1.1
1.0
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0.0
0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000 13000 14000 15000 16000 17000 18000 19000 20000 21000 22000 23000 24000
f [cpm]

Lab Data
 Misalignment
 Tire Element Coupling
 Allowable 0.0625” Misalignment
 Set with severe Misalignment
 Used Pruftechnik Shaft Alignment Tool
 Both Proximity Probes and FDS Sensors Reflect the Malfunction Better
Near the coupling
 Similar Frequency Content

Lab Data
 Misalignment
Velocity Y
X
v op [inch/ s] Rotor Kit Sof t Coupling Misa li gnment\ IB Ac c el N\ 1099 ACC FFT on FD S Rot or 3/ 6/ 2019 1: 35: 55 PM v op [inch/ s] Rotor Kit Sof t Coupling Misa li gnment\ IB Ac c el S\ 1099 ACC FFT on FD S Rotor 3/ 6/ 2019 1:37:06 PM
0.0090 0.0090
0.0085 0.0085
0.0080 RPM : 1800 (30.00Hz) 0.0080 RPM : 1800 (30.00Hz)

M(x) : 1050.00 cpm (0.58 Orders) M(x) : 1050.00 cpm (0.58 Orders)
0.0075 M(y) : 0.00639 inch/ s 0.0075 M(y) : 0.00443 inch/ s
0.0070 0.0070
0.0065 M 0.0065
0.0060 0.0060
0.0055 0.0055
0.0050 0.0050
0.0045 0.0045 M
0.0040 0.0040
0.0035 0.0035
0.0030 0.0030
0.0025 0.0025
0.0020 0.0020
0.0015 0.0015
0.0010 0.0010
0.0005 0.0005
0.0000 0.0000
0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000 13000 14000 15000 16000 17000 18000 19000 20000 21000 22000 23000 24000 0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000 13000 14000 15000 16000 17000 18000 19000 20000 21000 22000 23000 24000
f [cpm] f [cpm]
Insight FDS Data

strain [ue] Rotor Kit Sof t Coupling Misa li gnment\ IB St ra in BDC\ 1102 Strain spec trum on Lab Rot or 3/ 6/ 2019 1: 42: 17 PM strain [ue] Rotor Kit So f t Co uplin g Misalignment\ IB St ra in 430\ 1102 St ra in spec trum on Lab Rotor 3/ 6/ 2019 1: 43: 42 PM
0.16 0.110
0.105
0.15
0.100
RPM : 1800 (30.00Hz) RPM : 1800 (30.00Hz)
0.14
M(x) : 1050.00 cpm (0.58 Orders) 0.095 M(x) : 1050.00 cpm (0.58 Orders)
M(y) : 0.10 ue M(y) : 0.08 ue
0.13 0.090
M
0.085
0.12
0.080
0.11 0.075
M
0.10 0.070
0.065
0.09
0.060
0.08 0.055
0.050
0.07
0.045
0.06
0.040
0.05 0.035
0.030
0.04
0.025
0.03 0.020
0.02 0.015
0.010
0.01
0.005
0.00 0.000
0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000 13000 14000 15000 16000 17000 18000 19000 20000 21000 22000 23000 24000 0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000 13000 14000 15000 16000 17000 18000 19000 20000 21000 22000 23000 24000
f [cpm] f [cpm]

Lab Data
 Misalignment
Proximity Y
s pp [mils] R ot or Kit Sof t Couplin g Misali gnmen t\ IB Prox N \ 1098 D isp FFT on FDS R otor 3/ 6/ 2019 1:39:05 PM
X s pp [mils] Rotor Kit Soft Coupli ng Misalig nment\ IB Pro x S\ 1098 Disp FFT on FDS Rot or 3/ 6/ 2019 1: 39: 06 PM
0.22
0.34
0.21
M
0.32 M 0.20
RPM : 1800 (30.00Hz) RPM : 1800 (30.00Hz)
0.30 M(x) : 1050.00 cpm (0.58 Orders) 0.19 M(x) : 1050.00 cpm (0.58 Orders)
M(y) : 0.31051 mils M(y) : 0.19928 mils
0.18
0.28
0.17
0.26
0.16
0.24 0.15
0.22 0.14
0.13
0.20
0.12
0.18
0.11
0.16 0.10
0.14 0.09
0.08
0.12
0.07
0.10
0.06
0.08 0.05
0.06 0.04
0.03
0.04
0.02
0.02
0.01
0.00 0.00
0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000 13000 14000 15000 16000 17000 18000 19000 20000 21000 22000 23000 24000 0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000 13000 14000 15000 16000 17000 18000 19000 20000 21000 22000 23000 24000
f [cpm] f [cpm]
Insight FDS Data

strain [ue] Rotor Kit Sof t Coupling Misa li gnment\ IB St ra in BDC\ 1102 Strain spec trum on Lab Rot or 3/ 6/ 2019 1: 42: 17 PM strain [ue] Rotor Kit So f t Co uplin g Misalignment\ IB St ra in 430\ 1102 St ra in spec trum on Lab Rotor 3/ 6/ 2019 1: 43: 42 PM
0.16 0.110
0.105
0.15
0.100
RPM : 1800 (30.00Hz) RPM : 1800 (30.00Hz)
0.14
M(x) : 1050.00 cpm (0.58 Orders) 0.095 M(x) : 1050.00 cpm (0.58 Orders)
M(y) : 0.10 ue M(y) : 0.08 ue
0.13 0.090
M
0.085
0.12
0.080
0.11 0.075
M
0.10 0.070
0.065
0.09
0.060
0.08 0.055
0.050
0.07
0.045
0.06
0.040
0.05 0.035
0.030
0.04
0.025
0.03 0.020
0.02 0.015
0.010
0.01
0.005
0.00 0.000
0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000 13000 14000 15000 16000 17000 18000 19000 20000 21000 22000 23000 24000 0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000 13000 14000 15000 16000 17000 18000 19000 20000 21000 22000 23000 24000
f [cpm] f [cpm]

Lab Data
 Oil Whirl
 Occurs in Plain Bearings at Higher Speeds and Low Eccentricity
 Sub-synchronous
 L/D Whirl ½ x RPM
 Caused by Tangential Forces
 Whirl frequency varies with eccentricity

 Low eccentricity: whirl closer to 50%
 High eccentricity: whirl closer to 20%
 Can be higher than 50% with pre-swirl
 Much lower than 50% with anti-swirl
 Correct by increasing eccentricity

Lab Data
 Oil Whip
 Occurs when shaft vibrates at a natural frequency regardless of shaft speed
 Most commonly excited by whirl
 Can initiate without whirl
 Influenced by Viscocity, Temp, Load
 0.42 - 0.48 X RPM

Lab Data
 Oil Whip
 When Oil Whirls resonates

Lab Data
 Oil Whirl / Whip
Velocity Data
v op [inch/ s] R otor Kit Oil W hip \ IB Ac c el N \ 1099 ACC FFT on FDS R otor 2/ 28/ 2019 3:09:42 PM
0.030
0.029
0.028
0.027
RPM : 1987 (33.12Hz)
0.026 M(x) : 1987.50 cpm (1.00 Orders)
0.025 M(y) : 0.00909 inch/ s
0.024
0.023
0.022
0.021
0.020
0.019
0.018
0.017
0.016 (1327.50 / 0.01424)
0.015
0.014
0.013
0.012
0.011
(1987.50 / 0.00909)
0.010
M
0.009
0.008
0.007
0.006
0.005
0.004
0.003
0.002
0.001
0.000
0 2000 4000 6000 8000 10000 12000 14000 16000 18000 20000 22000 24000
f [cpm]
Insight FDS Data strain [ue] R otor Kit Oil W hip\ IB Strain BD C\ 1102 Strain sp ec trum on Lab Rotor 2/ 28/ 2019 3:15:13 PM
0.110
0.105
(1320.00 / 0.10)
0.100
RPM : 1987 (33.12Hz)
0.095 M(x) : 2655.00 cpm (1.34 Orders)
M(y) : 0.08 ue
0.090 (2655.00 / 0.08)
0.085 M
0.080
0.075
0.070
0.065
0.060
0.055
0.050
0.045
0.040
0.035 (1995.00 / 0.03)
0.030
0.025 (675.00 / 0.02)
0.020
0.015
0.010
0.005
0.000
0 2000 4000 6000 8000 10000 12000 14000 16000 18000 20000 22000 24000
f [cpm]

Lab Data
 Oil Whirl / Whip
Proximity Data
s pp [mils] R otor Kit Oil W hip \ IB Prox N \ 1098 D is p FFT on FD S R otor 2/ 28/ 2019 3:13:00 PM
0.34
(1327.50 / 0.31670)
0.32
RPM : 1987 (33.12Hz)
0.30 M(x) : 1987.50 cpm (1.00 Orders)
M(y) : 0.10255 mils
0.28
0.26
0.24
0.22
0.20
0.18
0.16
0.14
0.12 (1987.50 / 0.10255)
M
0.10
0.08
0.06
(660.00 / 0.01938)
0.04
0.02
0.00
0 2000 4000 6000 8000 10000 12000 14000 16000 18000 20000 22000 24000
f [cpm]
Insight FDS Data strain [ue] R otor Kit Oil W hip\ IB Strain BD C\ 1102 Strain sp ec trum on Lab Rotor 2/ 28/ 2019 3:15:13 PM
0.110
0.105
(1320.00 / 0.10)
0.100
RPM : 1987 (33.12Hz)
0.095 M(x) : 2655.00 cpm (1.34 Orders)
M(y) : 0.08 ue
0.090 (2655.00 / 0.08)
0.085 M
0.080
0.075
0.070
0.065
0.060
0.055
0.050
0.045
0.040
0.035 (1995.00 / 0.03)
0.030
0.025 (675.00 / 0.02)
0.020
0.015
0.010
0.005
0.000
0 2000 4000 6000 8000 10000 12000 14000 16000 18000 20000 22000 24000
f [cpm]

Lab Data
 Loss of pressure wedge

 Hydrodynamic Bearings Make Internal Pressure for Lift from the Babbitt
 Function of Static Load, Dynamic Viscosity, Shaft Speed
 Lose Hydrodynamic Pressure Wedge If
 High Static Load
Likely Constant
 Low Viscosity
High Temperatures Most Likely Cause
 Slow Shaft Speed
During Startup and Coast down

Lab Data

 Next Slide Demonstrates Losing Pressure Wedge
 Slowing Shaft Speed
 Note Large Increase in Strain at Bottom Dead Center
 Note Slight Decrease in Strain at Other Sensors
 The Shaft is No Longer Lifted
 Most of Strain is from Gravity Load

Lab Data
Before
After

Lab Data
 Loss oil feed

 Hydrodynamic and hydrostatic bearings require constant oil supply to flood the
bearing
 Losing oil feed can quickly lead to catastrophic failure
 Using strain gives immediate detection and shutdown options
 Note the bottom dead center strain amplitude which rises
(262%) instantly with loss of feed
 Note insignificant change (10%) in proximity probe displacement

Lab Data
 Loss of oil feed
 Before  After Cutting Feed

Lab Data
Velocity Data (1x from 0.003ips to 0.00472ips)
v op [inch/ s] Rotor Kit Loss of Oi l Fe ed\ I B Ac c el N\ 1099 ACC FFT on FD S Rotor 2/ 28/ 2019 3:24:00 PM
0.0100
0.0095
0.0090
RPM : 1800 (30.00Hz)
M(x) : 1072.50 cpm (0.60 Orders)
0.0085 M(y) : 0.00472 inch/ s
0.0080
0.0075
0.0070
0.0065
0.0060
0.0055
0.0050
M
0.0045
0.0040
0.0035
0.0030
0.0025
0.0020
0.0015
0.0010
0.0005
0.0000
0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000 13000 14000 15000 16000 17000 18000 19000 20000 21000 22000 23000 24000
f [cpm]
Insight FDS Data (1x from 0.32με to 1.22με)

strain [ue] R ot or Kit Loss of Oil Feed\ I B Stra in BD C\ 1102 St ra in spec tru m on Lab R otor 2/ 28/ 2019 3:28: 31 PM
1.40
1.35
1.30
1.25 M RPM : 1800 (30.00Hz)
1.20 M(x) : 1080.00 cpm (0.60 Orders)
M(y) : 1.22 ue
1.15
1.10
1.05
1.00
0.95
0.90
0.85
0.80
0.75
0.70
0.65
0.60
0.55
0.50
0.45
0.40
0.35
0.30
0.25
0.20
0.15
0.10
0.05
0.00
0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000 13000 14000 15000 16000 17000 18000 19000 20000 21000 22000 23000 24000
f [cpm]

Lab Data
Proximity Data (1x from 0.19mils to 0.177mils)
s pp [mils] Rotor Kit Loss of Oil Feed\ I B Pro x N\ 1098 Disp FFT on FD S Rotor 2/ 28/ 2019 3: 26: 01 PM
0.24
0.23
0.22
RPM : 1800 (30.00Hz)
0.21
M(x) : 1072.50 cpm (0.60 Orders)
0.20 M(y) : 0.17683 mils
0.19
0.18 M
0.17
0.16
0.15
0.14
0.13
0.12
0.11
0.10
0.09
0.08
0.07
0.06
0.05
0.04
0.03
0.02
0.01
0.00
0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000 13000 14000 15000 16000 17000 18000 19000 20000 21000 22000 23000 24000
f [cpm]
Insight FDS Data (1x from 0.32με to 1.22με)

strain [ue] R ot or Kit Loss of Oil Feed\ I B Stra in BD C\ 1102 St ra in spec tru m on Lab R otor 2/ 28/ 2019 3:28: 31 PM
1.40
1.35
1.30
1.25 M RPM : 1800 (30.00Hz)
1.20 M(x) : 1080.00 cpm (0.60 Orders)
M(y) : 1.22 ue
1.15
1.10
1.05
1.00
0.95
0.90
0.85
0.80
0.75
0.70
0.65
0.60
0.55
0.50
0.45
0.40
0.35
0.30
0.25
0.20
0.15
0.10
0.05
0.00
0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000 13000 14000 15000 16000 17000 18000 19000 20000 21000 22000 23000 24000
f [cpm]

Lab Data
Acceleration Data
a [g] R otor Kit Loss of Oil Feed\ I B Ac c el N \ 1101 Ac c TW F FDS Lab 2/ 28/ 2019 3: 23:44 PM
0.30
0.28
0.26
0.24
RPM : 1800 (30.00Hz)
0.22
0.20
0.18
0.16
0.14
0.12
0.10
0.08
0.06
0.04
0.02
0.00
-0.02
-0.04
-0.06
-0.08
-0.10
-0.12
-0.14
-0.16
-0.18
-0.20
-0.22
-0.24
-0.26
-0.28
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250
t [ms]
Insight FDS Data

strain [ue] R otor Ki t Loss of Oil Fe ed\ IB Strain BDC\ 1103 Stra in W av ef orm on Lab R otor 2/ 28/ 2019 3:28: 44 PM
5.0
4.5
4.0
RPM : 1800 (30.00Hz)
3.5
3.0
2.5
2.0
1.5
1.0
0.5
0.0
-0.5
-1.0
-1.5
-2.0
-2.5
-3.0
-3.5
-4.0
-4.5
-5.0
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250
t [ms]

Lab Data
Proximity Data
s [mils] R otor Kit Loss of Oil Feed\ I B Pro x N \ 1100 D isp T W F FD S R otor 2/ 28/ 2019 3:26:16 PM
0.35
0.30
RPM : 1800 (30.00Hz)

0.25
0.20
0.15
0.10
0.05
0.00
-0.05
-0.10
-0.15
-0.20
-0.25
-0.30
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250
t [ms]
Insight FDS Data

strain [ue] R otor Ki t Loss of Oil Fe ed\ IB Strain BDC\ 1103 Stra in W av ef orm on Lab R otor 2/ 28/ 2019 3:28: 44 PM
5.0
4.5
4.0
RPM : 1800 (30.00Hz)
3.5
3.0
2.5
2.0
1.5
1.0
0.5
0.0
-0.5
-1.0
-1.5
-2.0
-2.5
-3.0
-3.5
-4.0
-4.5
-5.0
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250
t [ms]

Lab Data
 Cocked Bearing Details

 Mounting strain sensors on both faces on the bearing can indicate a cocked bearing
during slow roll
 At higher speeds, many malfunctions can influence these values so only applicable at
slow roll (or even turning by hand)
Lab rotor bearing to bearing alignment checked and adjusted this way

Lab Data
 Cocked Bearing Details
High Low Strain

Strain
Low Strain High

Note: Strains should Strain
be similar on both
faces of the bearing
during slow roll

Lab Data
 Rub between shaft and Babbitt

 Dwelling Near Resonance to Force a Rub
 Mode Shape Bends the Shaft Causing the Rub
Slide Shows Outboard Bearing (High Clearance)

 Strain in Upper Half and Displacement in Lower Half
 Displacement Waveform Hints at Rub
 Strain Waveforms Clearly Present the Rub

Lab Data
Velocity Data
v op [inch/ s] Rot or Kit Rub\ IB Ac c el N\ 1099 ACC FFT on FD S Rotor 2/ 28/ 2019 2:34:36 PM
0.044
0.042
0.040 RPM : 1800 (30.00Hz)

M(x) : 1275.00 cpm (0.71 Orders)
0.038 M(y) : 0.03653 inch/ s
M
0.036
0.034
0.032
0.030
0.028
0.026
0.024
0.022
0.020
0.018
0.016
0.014
0.012
0.010
0.008
0.006
0.004
0.002
0.000
0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000 13000 14000 15000 16000 17000 18000 19000 20000 21000 22000 23000 24000
f [cpm]
Insight FDS Data strain [ue] Rotor Ki t R ub\ IB St ra in BDC\ 1102 St ra in sp ec t ru m on Lab R ot or 2/ 28/ 2019 2:43: 38 PM
3.4
3.2
RPM : 1800 (30.00Hz)
3.0 M(x) : 1275.00 cpm (0.71 Orders)
M(y) : 2.83 ue
M
2.8
2.6
2.4
2.2
2.0
1.8
1.6
1.4
1.2
1.0
0.8
0.6
0.4
0.2
0.0
0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000 13000 14000 15000 16000 17000 18000 19000 20000 21000 22000 23000 24000
f [cpm]

Lab Data
Proximity Data
s pp [mils] Rot or Kit Rub\ I B Pro x S\ 1098 Disp FFT on FDS Rot or 2/ 28/ 2019 2:38: 10 PM
1.6
1.5
RPM : 1800 (30.00Hz)

1.4 M M(x) : 1275.00 cpm (0.71 Orders)
M(y) : 1.36719 mils
1.3
1.2
1.1
1.0
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0.0
0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000 13000 14000 15000 16000 17000 18000 19000 20000 21000 22000 23000 24000
f [cpm]
Insight FDS Data strain [ue] Rotor Ki t R ub\ IB St ra in BDC\ 1102 St ra in sp ec t ru m on Lab R ot or 2/ 28/ 2019 2:43: 38 PM
3.4
3.2
RPM : 1800 (30.00Hz)
3.0 M(x) : 1275.00 cpm (0.71 Orders)
M(y) : 2.83 ue
M
2.8
2.6
2.4
2.2
2.0
1.8
1.6
1.4
1.2
1.0
0.8
0.6
0.4
0.2
0.0
0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000 13000 14000 15000 16000 17000 18000 19000 20000 21000 22000 23000 24000
f [cpm]

Lab Data
Acceleration Data
a [g] R otor Kit R ub\ I B Ac c el S\ 1101 Ac c TW F FDS Lab 2/ 28/ 2019 2: 35:33 PM
0.60
0.55
0.50
RPM : 1800 (30.00Hz)
0.45
0.40
0.35
0.30
0.25
0.20
0.15
0.10
0.05
0.00
-0.05
-0.10
-0.15
-0.20
-0.25
-0.30
-0.35
-0.40
-0.45
-0.50
-0.55
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250
t [ms]
Insight FDS Data strain [ue] Rotor Kit Rub\ IB Stra in BDC\ 1103 St ra in W av eform on Lab Rot or 2/ 28/ 2019 2: 44:08 PM
8
RPM : 1800 (30.00Hz)

6
-1
-2
-3
-4
-5
-6
-7
-8
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250
t [ms]

Lab Data
Proximity Data
s [mils] Rot or Kit Rub\ IB Prox S\ 1100 Disp T W F FD S Rot or 2/ 28/ 2019 2: 38: 25 PM
1.0
0.9
0.8
RPM : 1800 (30.00Hz)
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0.0
-0.1
-0.2
-0.3
-0.4
-0.5
-0.6
-0.7
-0.8
-0.9
-1.0
-1.1
-1.2
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250
t [ms]
Insight FDS Data strain [ue] Rotor Kit Rub\ IB Stra in BDC\ 1103 St ra in W av eform on Lab Rot or 2/ 28/ 2019 2: 44:08 PM
8
RPM : 1800 (30.00Hz)

6
-1
-2
-3
-4
-5
-6
-7
-8
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250
t [ms]

Field Data
 Waukesha engine – (BP Oil)

 Waukesha Natural Gas Engine
 1st Ever Test of Dynamic Strain on Main Bearings by Pioneer Engineering
 Used old style metal foil strain gauges for proof of concept
 Now use IEPE powered piezoelectric strain sensors
 No malfunctions noted
 Examples of Clear Waveforms from Engine Main Bearings

Field Data
Installation pictures

Field Data
Insight FDS

Field Data
Insight FDS

Field Data
Insight FDS

Field Data
Insight FDS

Field Data
 PA Fan Motor - Rotor Fault (Basin Electric)

 4 pole AC induction motor (1500HP)
 2 Stage vane axial fan
 Motor has a known rotor bar fault
 Data taken on motor outboard bearing with
Insight FDS
Case mounted accelerometer
Proximity probes
 Prox probe data was not
slow roll compensated

Field Data
 PA Fan Motor - Rotor Fault
Unfiltered TWF - Insight FDS

Field Data
Unfiltered TWF - Accelerometer

Field Data
Unfiltered TWF - Prox Probe

Field Data
FFT - Insight FDS

Field Data
FFT - Accelerometer

Field Data
FFT - Prox Probe

Field Data
High Res. FFT - Insight FDS

Field Data
High Res. FFT - Accelerometer

Field Data
High Res. FFT - Prox Probe

Conclusion
 Fluid Film Bearings on Critical Machines
 Different monitoring technologies

 Proximity Probes – Best but very expensive
 Temperature – To late warning
 Case Mounted Accelerometers – Better than nothing
 Not at all?? – Expensive
 Insight Force Detection Sensor

 Strain indirectly representing bearing forces
 Easy install
 Data quality proven
 New exciting technology available today.

THANK YOU
QUALITY MEANS TO US:
TO MAKE A DIFFERENCE EVERY DAY.
www.pruftechnik.com

FDS - A Revolution in Fluid Film Bearing Monitoring

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FDS - A Revolution in Fluid Film Bearing Monitoring

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Revolution in Fluid Film Bearing Monitoring

Insight Force Detection Sensor

© PRUFTECHNIK Inc. Author: Dries Van Loon Slide 1

© PRUFTECHNIK Inc. Author: Dries Van Loon Slide 2

© PRUFTECHNIK Inc. Author: Dries Van Loon Slide 3

 Case Mounted Vibration

© PRUFTECHNIK Inc. Author: Dries Van Loon Slide 4

© PRUFTECHNIK Inc. Author: Dries Van Loon Slide 5

 Other monitoring techniques not sufficient individually

 Need for innovation

 Insight Force Detection Sensor

© PRUFTECHNIK Inc. Author: Dries Van Loon Slide 6

© PRUFTECHNIK Inc. Author: Dries Van Loon Slide 7

Use dynamic strain sensor on the housing of a fluid film bearing,

© PRUFTECHNIK Inc. Author: Dries Van Loon Slide 8

© PRUFTECHNIK Inc. Author: Dries Van Loon Slide 9

 Technical Specs (PTA-FDS102-VOY)

© PRUFTECHNIK Inc. Author: Dries Van Loon Slide 10

 Technical Specs (PTA-FDS101-VOY)

© PRUFTECHNIK Inc. Author: Dries Van Loon Slide 11

© PRUFTECHNIK Inc. Author: Dries Van Loon Slide 12

© PRUFTECHNIK Inc. Author: Dries Van Loon Slide 13

 Measure (as ICP sensor)

© PRUFTECHNIK Inc. Author: Dries Van Loon Slide 14

 Measure (as ICP sensor)

 Handheld data collector (does not have to be Pruftechnik device)

© PRUFTECHNIK Inc. Author: Dries Van Loon Slide 15

 Measure (as ICP sensor)

 Continuous Monitoring (does not have to be Pruftechnik device)

© PRUFTECHNIK Inc. Author: Dries Van Loon Slide 16

© PRUFTECHNIK Inc. Author: Dries Van Loon Slide 17

 PTA-MT-MK04-VOY - Installation Kit (for FDS102) - $100

PTA.SCA-1032F-BNCM.VO - Adapter (10-32F to BNCM, 3ft) - 50.00 $

 Installation cost <<< compared to retrofit prox. Probes (shutdown time)

© PRUFTECHNIK Inc. Author: Dries Van Loon Slide 18

© PRUFTECHNIK Inc. Author: Dries Van Loon Slide 19

© PRUFTECHNIK Inc. Author: Dries Van Loon Slide 20

© PRUFTECHNIK Inc. Author: Dries Van Loon Slide 21

© PRUFTECHNIK Inc. Author: Dries Van Loon Slide 22

© PRUFTECHNIK Inc. Author: Dries Van Loon Slide 23

- Timewave form - detail

© PRUFTECHNIK Inc. Author: Dries Van Loon Slide 24

 Lab Rotor Setup

© PRUFTECHNIK Inc. Author: Dries Van Loon Slide 25

 Velocity  Dynamic Strain

0.35 (1245.00 / 0.30)

© PRUFTECHNIK Inc. Author: Dries Van Loon Slide 26

 Acceleration  Dynamic Strain

© PRUFTECHNIK Inc. Author: Dries Van Loon Slide 27

 Proximity Displacement  Dynamic Strain

(1515.00 / 0.76715) (1515.00 / 0.77)

0.35 0.35 (1245.00 / 0.30)

© PRUFTECHNIK Inc. Author: Dries Van Loon Slide 28

 Proximity Displacement  Dynamic Strain

© PRUFTECHNIK Inc. Author: Dries Van Loon Slide 29

© PRUFTECHNIK Inc. Author: Dries Van Loon Slide 30

RPM : 1970 (32.84Hz)

© PRUFTECHNIK Inc. Author: Dries Van Loon Slide 31

© PRUFTECHNIK Inc. Author: Dries Van Loon Slide 32

RPM : 1800 (30.00Hz)

Insight FDS Data – 1x = 1.46με

1.6 RPM : 1800 (30.00Hz)

© PRUFTECHNIK Inc. Author: Dries Van Loon Slide 33