Vigilance 4.

0 training

Blade holder vibration monitoring

and analysis
January 2019
Vigilance 4.0 training
Chapter 0 – Introduction

a/ General

© BTG CONFIDENTIAL
Definitions

Vibration is a mechanical phenomenon whereby oscillations

occur about an equilibrium point

Vibration is quantified by the number of occurrences of a

repeating event or cycles per unit time called Frequency

For counts per unit of time, the SI unit for frequency is the
hertz (Hz). 1 Hz means that an event repeats once per
second
 Simple Harmonic Motion

A traditional unit of measure used with rotating mechanical

devices is revolutions per minute, abbreviated RPM
60 RPM equals one hertz.
y 1 revolution
Unbalance due to +
heavy weight

Amplitude
0 T
x

-
Displacement measurement
Rotation from 0 position over x axis
3600 RPM = 3600 cycles per minute = 60 Hz (60 cycles per second)
Other vibration types

Free vibration occurs when a Occurs when a steady input of

mechanical system is set off with energy is converted into
an initial input and then allowed movement that has
to vibrate freely characteristics of frequency and
amplitude
= Defect on Yankee = Friction
 Vibration amplitudes

Displacement
▪ Usually measured microns

Velocity
▪ Measured in meter per second

Acceleration
▪ Measured in G or in m/sec2
▪ One G (Gravity) is equal to 9.81 m/sec2

Acceleration usually preferred since it better indicates

energy involved into vibration
Vibration amplitude measurement
RMS Root Mean Square
▪ Square root of the average of the squared values of the
waveform
▪ “Average” level of vibration
▪ Arithmetical average calculation never used in vibration
analysis

Waveform

These two
surfaces «Squared»
are equal

RMS level
Vibration amplitude measurement

Peak
▪ Maximum excursion of the wave from the zero or
equilibrium point

Peak level
Vibration amplitude measurement
Summary
Average
Peak

RMS

Peak to Peak
Vibration signal analysis

Temporal analysis
▪ Show evolution of vibration amplitude over the time
▪ Allow detection of process event on vibration level
Amplitude

Time

FFT – Fast Fourier Transformation

▪ It let migrate from Temporal to Frequency Domain
▪ It separates the individual frequencies
▪ It shows the vibration amplitudes for each frequency
FFT - Fast Fourier Transformation
Vigilance 4.0 training
Chapter 0 – Introduction

b/ Tissue Process and Blade vibration

 Sources of vibration on tissue machine

Pumps Motor Fans Rolls Doctors

© Andritz AG 2007. All rights reserved. No part of this copyrighted work may be reproduced, modified or distributed in any form or by any means, or stored in any database or retrieval system, without the prior written permission of
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 Sources of vibration on tissue machine

Numerous elements can vibrate on tissue machine

▪ Pump, motor, fan, etc..
▪ Vibration transferred to machine structure

Most hazardous vibrations generated at doctors

▪ Friction with cylinder surface
▪ Also undergoing structure vibration

Doctor vibration = friction vibration + structure vibration

 Friction definition
Friction is the force resisting the relative motion of elements
sliding against each other
▪ Deformation and wear
▪ Friction welding
▪ Vibration
Pin jump = Adhesion points of pin
vibration (friction)
Vibration composition

Each element has its own vibration signature

▪ Unbalance
▪ Forced vibration
▪ Friction

Vibration measurement at blade is a composition

 Vibration composition - Roll
+

Amplitude
0

1 revolution

Yankee = 120 cycles per minute = 2 Hz (2 cycles per second)

Press = 475 cycles per minute = 8Hz
Felt roll = 1430 cycles per minute = 24Hz
Vibration composition - Fans

Amplitude
0 T

1000 RPM 1 revolution

4 blades = Vibration appears 4 times in one revolution

4 X 1000 RPM = Vibration appears at 4000 cycles per min.
= 67 Hz
 Vibration composition - Gearbox

Amplitude
0

1000 RPM
1 revolution

12 teeth engage in one revolution = vibration appears 12 times in one revolution

12 x 1000 RPM = vibration appears 12,000 times in one minute
= 12,000 CPM
= 200 Hz
Waves shape - Comparison & frequencies
+

0
Frequency

1x
+
-

Frequency
- 4x
+

Frequency
- 12x
Vibration composition

+
+ λ

0 0

- -
Harmonic vibrations

A component frequency of the signal that is

an integer multiple of the fundamental frequency
if the fundamental frequency (first harmonic) is 25 Hz, the
frequencies of the next harmonics are: 50 Hz (2nd
harmonic), 75 Hz (3rd harmonic), 100 Hz (4th harmonic)
etc.
 Harmonic vibrations

▪ For blade, harmonics corresponds to the various

vibration/bending shape the blade can take alternatively
Vigilance 4.0 training
Chapter 0 – Introduction

c/ Vigilance system
Acceleration Sensor

Accelerometer or vibration sensor

▪ Piezoelectric type = vibration impose a force from the
mass on piezoelectric crystal which generate an electrical
charge that is relative to the applied force
▪ Measure vibration perpendicular to contact surface
Mass Piezoelectric
material

Preloaded
Amplifier
stud
Electrical
connector
Vigilance System Principle

Detection of vibration coming from blade(s) with sensor(s)

Acquisition and treatment of vibration data by V-box
Analysis and display of vibration signals with software

parcView

IPC
VSE
V-Box

Tags from DCS

Vibration signal analysis

Sensor signal sampled every 50ms

▪ To measure Peak value
▪ To calculate RMS value

Signal decomposed with FFT to

▪ Create Vibration Indicators (VI) on specific frequency
bands
▪ For each VI
▪ Measure RMS
▪ Set Alarm and Danger level
▪ All a temporal analysis
Software capabilities
FFT analysis of the vibration signal
Machine vibration footprint or signature
▪ Helps defining critical vibration range
▪ Enables to discriminate vibration source
Software capabilities
Level of vibration for selected frequencies
Vibration monitoring by operator
▪ Follows a specific critical frequency range
▪ Configurable alarm & danger levels
▪ Reaching these levels triggers counteractions
Software capabilities
Follow-up of vibration signal of each sensor
Temporal analysis of vibration
▪ Possible for each specific critical frequency range
▪ Clear analysis of process events
▪ Best diagnostic tool to improve situation
Vigilance 4.0 training
Chapter 1 – Vibration monitoring

Blade holder vibration monitoring

and analysis
January 2019
Vigilance 4.0 Quick User Guide
 Blade life
Measured in hours
Current blade is Home Page View
moving needle
FFT
Live snapshot of
FFT spectrum
Damage level view
Grey: damage indicator
Number: mg of
acceleration
Name: corresponds to
specific Yankee process
frequency

Damage Level
Accumulation
Integrates blade total
vibration over time.
Steeper line indicate
blade wearing fast OR
harder coating
Vigilance 4.0: Navigation

Click a tile to go
through to more
detailed page. This
tile takes you to
trends
 Creping damage level trend

More details?
Right click and
Zoom in
select “Smart
Click and drag on trend
Mouse”. Roll mouse
to select area of
cursor over trends
interest and then Click
to see exact values
“Z” button to magnify
view. Click “X” to return
default view.
Double time scale Shift time
Click double arrow Click and drag on
to double time time scale to pan
scale view
Home
Click to return
to home
screen
 Vigilance 4.0: Navigation

Click here for

spectrum view
 Expanded spectrum

FFT/Damage Level View FFT Historian

Live FFT is overlayed on Blue: low intensity
live damage level Red: high intensity
indicators. Use this to see
specific frequency
response
Intensity

Time

0 kHz to 20 kHz 0 kHz to 20 kHz

 Expanded spectrum

Blade unloaded
Blue line across
No signal
spectrum
Straight vertical
lines. Check V-box
Headers power.

Edges

Hard
coating Time controls
Intensity

Time
Same time axis
High controls as in
frequency trends

0 kHz to 20 kHz 0 kHz to 20 kHz

 Vigilance 4.0: Navigation

Click here for

blade change
log
 Blade Change Log

4. Save data

1. Add new record 3. Manually

Current time is 2. Type in blade number enter blade
automatically Usually found on blade change
selected label reason here
Vigilance 4.0: Navigation

Click here for

help pages
 Help page (to be translated)

Click here for

advice about the
alarm condition

Click here for a

vibration
troubleshoot Click here for a
flowchart checklist of
vibration initiators
Vigilance 4.0 training
Chapter 3 – Maintenance and Troubleshooting

Troubleshooting and preventive

actions
January 2019
Vigilance 4.0 troubleshooting
Failure mode Cause Solution Prevent/prepare
Compute Stick failure Replace with spare Have a spare onsite. If no spare, use any
Black screen laptop and RDP to [Link]
Screen failure Replace
No V-box power Reconnect
Disconnected
Network failure Fix cables Make quality teminations
from V-box
IPC failure BTG to restore IPC from backup Maintain cooling air supply

VSE failure Replace VSE Have a spare onsite

Sensor cable failure Replace whole cable Avoid fires around blade holder. Protect
No vibration cables with flexible metal tubes.
signal Sensor failure Replace every 12 months. Avoid impacts on
sensors. Install protective shroud or plate.
IPC overheating Cooling air Maintain sufficient cooling. Also, updates
improve system performance over time
Slow system
Not up-to-date Call BTG for remote update Ensure remote support is available

© BTG – Confidential - Scorecard user guide Jan 2019