Utilizing UE and Vibration

Analysis in a CBM Program

Presented to Ultrasound World 2005

By Carey Repasz, Allied Reliability
November 8, 2005
Objectives

• Learn the capabilities of each technology

• Discuss advantages and limitations present to each
technology
• Demonstrate how UE and vibration analysis can be used
synergistically in a CBM program
Advantages of Mechanical UE

• Quick
• Cost Effective
• Flexible
• Minimal amount of technician training required
• Uses sensory elements for detection
• Sound data can be converted to standard vibration data
• Can be used to assist vibration monitoring in location
and classification of defects
Limitations of Mechanical UE

• Subjective
• Data is traditionally qualitative, not quantitative
• Data is difficult to trend
• Difficult to interpret in noisy environments
Advantages of Vibration Analysis

• Can detect a wide variety of machine failure modes

• Failure mode can be accurately categorized
– BPFI, BPFO, gear mesh, rotor bar, etc.
• Severity of defect can be accurately determined
• Quantitative data can be trended
Limitations of Vibration Analysis

• Requires high level of technical training

• Long data collection times for measurement of slow
speed machines
• Equipment Price
Vibration

• Vibration is the Forced Oscillation of the Mass in a

Spring Mass System in Equilibrium about a Stationary
Reference Point
Signal Modulation

• Signal modulation occurs when two related mechanical

events occur simultaneously
Demodulation

• Demodulation allows the frequency of the event to be

measured
Ultrasound

• High frequency sound waves which are above the range

of human hearing
• Between 20kHz and 300kHz
• Frequency of interest for mechanical UE is 28 to 32kHz
• Signal is heterodyned to audible range
Examples of Bearing Defects
Using UE and Vibration Together in the
CBM Program
• UE for condition based lubrication to extend bearing life
• Vibration for failure mode detection
• Feedback from UE lube technician to vibration technician
to assist in identification of early stage defects
• UE software can be used to generate an exception
report
• Inspection of demodulated vibration data can be used to
correlate the existence of defect frequencies
• Collect demodulated spectrum in routine vibration route
data
Methods for Trending UE Data

• Spreadsheet
– Record “As found” and “As left” readings
• UE Software
• Vibration Software
– Set up point in database, and record into data collector
Keys to Success

• Trend UE data and develop a system to generate

exception report
• Ensure that technologies compliment each other
• Use demodulated vibration data to classify defects
• Encourage technicians to communicate directly
• Record UE sound data for analysis
Questions
Speaker Biography – Carey Repasz
Program Manager, Allied Reliability
• Carey spent the last fifteen
years in maintenance with jet
aircraft for the US Air Force,
and industry in mining, steel,
plastics, pharmaceutical, paper
and food processing
• Ten years ago, Carey turned
his talents to the emerging field
of predictive maintenance,
where technologies such as
vibration, infrared and oil
analysis are used to make sure
that equipment runs faster,
costs less and never breaks
down
• Today he serves as the
Program Manager for Cargill
Corn Milling in Eddyville, Iowa
and oversees an Integrated
Reliability & Maintenance
Program which employs fifteen
predictive maintenance techs
• Carey lives in
Centerville, Iowa
with his wife and
three children and
enjoys fishing and
training his
hunting beagles in
his spare time