Vibration Analysis Overview

Transcription

1 Advanced Maintenance Technologies Services: Vibration Analysis Consultants Vibration Analysis Consulting Laser Alignment Services Predictive/Planned Maintenance Custom Training Ray W. Wonderly Certified Vibration Specialist ISO Certified Vibration Institute Emerson Process Advanced Maintenance Technologies Ray W. Wonderly ISO Certified Vibration Analyst Vibration Institute Emerson Process Predictive Technologies VIBRATION ANALYSIS Vibration Analysis Overview Introduction VIBRATION ANALYSIS AGENDA PURPOSE, SCOPE USING VIBRATION STANDARDS CASE HISTORIES BENEFITS OF VIBRATION ANALYSIS VIBRATION ANALYSIS PURPOSE, SCOPE TO DETECT POTENTIAL FAULTS OF EQUIPMENT, THAT LEFT UNDETECTED OR UNATTENDED, COULD LEAD TO CATASTROPHIC FAILURE OF EQUIPMENT. TO VERIFY AND ASSURE EQUIPMENT IS OPERATING SATISFACTORY AND AS REQUIRED TO CERTIFY NEW AND REBUILT EQUIPMENT USING VIBRATION STANDARDS TO ASSURE QUALITY OF OPERATION VIBRATION ANALYSIS PURPOSE, SCOPE EARLY DETECTION OF EQUIPMENT PROBLEMS TO ALLOW BETTER SCHEDULING OF MAINTENANCE WORK PERFORMED ON A AS NEEDED PROACTIVE BASIS VERSUS EMERGENCY OR CRISIS REPAIR PERFORM VIBRATION ANALYSIS AND TO ANALYZE, STORE AND TREND DATA FOR THE BENEFIT OF YOUR ORGANIZATION & RELIABILITY OF EQUIPMENT 1

2 Predictive Technologies Vibration Analysis (Root Cause) Infrared / Thermography Ultra Sound Laser Alignment Oil Analysis / Tribology Motor Current Analysis High Speed Video / Fiber Optics What Is Vibration Analysis Of all the parameters to measure equipment, the vibration signature contains the most information The vibration signature not only provides information concerning the severity of a problem, but it also points to the possible source, or root cause of the problem Vibration Analysis Substantial Reduction In Machinery Problems/Failures Extended Equipment Life Total Cost Savings Equipment Repairs, Maintenance & Plant Operations Vibration Analysis Strengths Will give very early detection of potential fault (problem) Will give you the root cause of a problem (Unbalance, Misalignment, Bearings, etc.) Cost Savings Less major maintenance minor repairs vs. major catastrophic repairs ALL MACHINES VIBRATE EXCESSIVE VIBRATION IS A PROBLEM 2

3 Frequency Domain (Spectra) ALL FAULT TYPES HAVE THEIR OWN CHARACTERISTIC VIBRATION PATTERNS Frequency & Amplitude Frequency Determines Type Of Fault Amplitude Determines Severity Of Fault Important Machine Information Operating (Reference) Speed Of Machine Components such as Motor, Pump, Blower Equipment Must Be Running Important Information Reference Speed Of All Components Bearing Information Belt Information Coupling Information # Vanes/Blades # Gear Teeth Safety When Working Around Rotating Equipment Operational Speed 3600 RPM = 60 RPS 1800 RPM = 30 RPS Always Lock Out Equipment When Performing Maintenance Work Types of Machinery Faults Unbalance Misalignment Mechanical Looseness Bearing Faults Vane & Blade Pass (Flow Disturbance) Gear Electrical (Air Gap, Stator, Rotor) 3

4 Vibration Analysis Program Database Structure Database & Equipment Structure Database Area Machine Train Machines (components) Measurement Points (measure types and alarms) Routes Acquire Data Established Routes Vibration Analyzer/Data Collector MIV MOV Download Data For Analysis/Reports MIA MIH MOH 4

5 Information Initial Baseline Measures Things Management Needs to Know Machine/ID Problem found explanation Recommendations Priority or urgency according to severity Trending Trending Fault Alarm Limit Trend Data Hoffman #2 Trending Before & After Repairs Fault Alarm Limit Fault Alarm Limit 5

6 Vibration Alarm Limit Threshold Vibration (Amplitude) Measures Amplitude is the maximum value of vibration at a given location Displacement (Mils PK PK) Velocity (IPS PK or RMS) Acceleration (G s) (Vibration) Amplitude Comparison Velocity & Displacement Spectra - Mass Unbalance Machine 1800 RPM.250 In/Sec Velocity (Peak) 2.6 Mils (.0026) Displacement Peak-Peak Forcing Freq.= 1X Turning Speed 1170 CPM or Hz Trend Data - Mass Unbalance Spectra - Misalignment High 1x & 2x Turning Speed 6

7 Spectra Mechanical Looseness Trend Data Mechanical Looseness Spectra Bearing Defect Spectra Mechanical Looseness Spectra Bearing Defect Spectra Bearing Defect 7

8 Spectra Bearing Defect Trend Bearing Defect City Of Eaton Water Treatment Facility Eaton, Ohio City Of Eaton Water Treatment Facility Vibration Analysis Program Implemented March 07, 2008 (Initial Baseline Measurements) Vibration Analysis Condition Monitoring on approximately 30 machines (pumps/blowers) Quarterly schedule (route structured) City Of Eaton Water Treatment Facility Successful Corrective Action Repairs Hoffman Blower #3 Bent Shaft Filter Backwash Pump #1 Misalignment/Looseness Filter Backwash Pump #2 Mechanical Looseness Water Treatment Backwash #1 - Misalignment Mudwell #2 Mechanical Looseness Hoffman #2 Misalignment/Looseness East Lift Station Pumps 1 & 2 - Bearings 8

9 AFTER REPAIRS Severe Misalignment & Worn Coupling.088 in/sec 1x Operation in/sec peak 1x Operation Speed BEFORE REPAIRS in/sec 1x Operation 9

10 MIV MOV MIA MIH MOH After Alignment:.017 1x Operation Speed.502 1x operation speed Before Alignment:.502 1x Operation Speed 10

11 Loose Bolts City Of Fairfield Water Treatment Facility Fairfield, Ohio Booster Station Pump EQUIPMENT: KAY DRIVE PUMP STATION #2 KAY DRIVE PUMP STATION #2 SURVEY DATE: JUNE 29, 2010 (Initial Baseline Measurements) FAULT TYPE: MECHANICAL LOOSENESS, COUPLING PROBLEM AND/OR BEARING DEFECT (PUMP) PRIORITY/URGENCY: HIGH PROBLEMS FOUND: Excessive vibration levels due to severe mechanical looseness of pump-inboard bearing (coupling side). Mechanical looseness of bearing area showing high frequency harmonics to operating speed. Time waveform shows very elevated acceleration levels in access of 20g s. RECOMMENDED ACTIONS: Assure mounting bolts of pump support and both bearings are secure. Inspect shaft coupling for damage and repair if needed. Check pump & motor shafts for looseness. Assure proper lubrication of pump coupling. Assure replacement parts/pump available for future repair. Loose Bolts Loose Bolts 11

12 Initial Baseline Measurements Severe Mechanical Looseness Pump #2 TREND DATA KAY DRIVE PUMP #2 After Repairs After Repairs TREND DATA KAY DRIVE PUMP #2 BEFORE & AFTER REPAIRS TREND DATA KAY DRIVE PUMP #2 After Repairs After Repairs Before Repairs After Repairs TREND DATA TREND DATA KAY DRIVE PUMP #2 Mechanical Looseness Bearing & Coupling After Corrective Action Repairs Pump #2 After Corrective Repairs After Repairs 12

13 City Of Fairfield Water Treatment Facility Fairfield, Ohio EQUIPMENT: BACKWASH PUMP #1 SURVEY DATE: SEPTEMBER 5, 2012 FAULT TYPE: UNBALANCE (MOTOR) PRIORITY/URGENCY: HIGH PROBLEMS FOUND: Excessive vibration levels due to unbalance of motor component. Vibration levels highest on outboard end of motor. RECOMMENDED ACTIONS: Check anti-backup clutch assembly (motor) for unbalance or damage. Check for proper amount of keystock of shaft key-way area of both motor and pump shaft and adjust length if needed. Balance motor if vibration levels increase. URGENCY: High BACKWASH PUMP BACKWASH PUMP.496 in/sec Velocity Fault Alarm Limit Fault Alarm Limit Historical Trend Data Historical Trend Data 13

14 Balance Weights BACKWASH PUMP BACKWASH PUMP After Balancing in/sec Before Balancing in/sec After Balancing in/sec Before Balancing in/sec Fault Alarm Limit Historical Trend Data After Balancing Montgomery County Western Regional Water Reclamation Facility 14

15 EQUIPMENT: DRAIN PUMP #4 SURVEY DATE: JUNE (ORIGINAL WRITE-UP) FAULT TYPE: WORN COUPLING & MISALIGNMENT PRIORITY/URGENCY: HIGH PROBLEMS FOUND: Excessive vibration levels due to possible worn coupling and misalignment of motor and positrol speed drive shafts. Very substantial increase in vibration levels since last survey. RECOMMENDED ACTIONS: Inspect condition of shaft coupling and repair/replace if needed. Drain Pump #4 Before & After Repairs Before & After Repairs 15

16 City Of Miamisburg Water Treatment Facility Miamisburg, Ohio Acceptance/Certification Testing New or Rebuilt Equipment EQUIPMENT: LINDEN AVE. BOOSTER PUMP #2 SURVEY DATE: AUGUST 28, 2012 FAULT TYPE: MISALIGNMENT & POSSIBLE WORN COUPLING PRIORITY/URGENCY: HIGH PROBLEMS FOUND: Excessive vibration levels due to misalignment of motor and pump shafts. RECOMMENDED ACTIONS: Check condition of shaft coupling insert. Precision laser align motor and pump shafts. URGENCY: High. Schedule corrective action repairs at next opportunity. Repaired Coupling Insert Linden Ave Booster Pump #2 16

17 Linden Ave Booster Pump #2 Linden Ave Booster Pump #2 Before & After Repairs.816 in/sec Velocity Fault Alarm Limit.130 in/sec Velocity.816 in/sec Velocity Linden Ave Booster Pump #2 Before & After Repairs 17

18 Last Data.063 Operation CONTACT INFORMATION: Ray Wonderly Advanced Maintenance Technologies Kiefer Rd. Germantown, OH Last Data 18