Professional Documents
Culture Documents
Presentation Outline
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Introduction
Maintenance Philosophies
Condition Monitoring Techniques Vibration Monitoring
Introduction
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equipments, machine and systems by observing, checking, measuring and monitoring critical parameters
Objective: The objective of the project is to identify the deteriorating condition
of centrifugal fans using Vibration measurement and to establish the basic condition of equipment which directly results in the enhanced safety, operational reliability, extends equipment life.
Centrifugal fans Air/gas flow rate: Nm3/hr Discharge pressure: mm WC Suction Pressure: mm WC Temp 0C Density kg/m3 Material of construction
Periodic
Off-line Condition monitoring On-line
Continuous
Continuous
Power stations
Process industry Air conveyors
Maintenance Philosophies
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Failure Based
Maintenance /Break down Maintenance Routine Maintenance/Preventive maintenance Design Out Maintenance Condition Based Maintenance
Vibration monitoring
Criticality Index
Selection equipment for Condition monitoring according
Vibration Monitoring
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Vibration monitoring is an
established technique for diagnostic and predictive maintenance of critical machineries of plant and industries.
What ,where, when & how
to monitor
Percentage Use of Various monitoring technique
Vibration Monitoring
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normal position. Velocity-speed at which that point moves. Frequency - The number of cycles that a vibrating object completes in one second is called frequency. Acceleration- Acceleration is a measure of how quickly speed changes with time Amplitude - Amplitude is the distance from the stationary position to the extreme position on either side.
Accelerometer
Active transducer electromechanical transducer
When accelerometer is vibrated, the force to vibrate the mass is passed
Accelerometer are user in most situations, particularly for structural and rotor support(bearing housing) vibration measurement
Demand
of economical design and high power density led to lighter structures and high operation speeds-led to highly stressed machinery
List critical machines Establish acceptable levels of machinery vibration Determine each machine condition and bring to near normal level
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Source
IMP BRG = Impeller Bearing V= Vertical, H= Horizontal, A= Axial. RPM = Resolution per Minute Take overall vibration reading if overall VIB. Exceeds alarm limit, use vibration analyser, record all readings.
UNIVERSITY OF PETROLEUM AND ENERGY STUDIES - DEHRADUN
bearing Damaged impellers Other defective components like bad pulleys/belts etc.
Finding Problems with Bearings and Rotating Equipment Using Vibration Analysis
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All data are based on 1 RPM (Revolutions Per Minute). If a machine is running 1800 RPM, we would multiply 1800 by the frequency in the chart to get BPFO, BPFI and BSF in Hertz. 17
For Example:
BPFI = .0836
.0836 X 1800 RPM = 150.48 Hz 150.48 Hz x 60 = 9028.8 CPM
BSF = .0295
.0295 X 1800 RPM = 53.1 Hz 53.1 Hz x 60 = 3186 CPM
We would look for spikes in the spectrum at 5367.6 CPM, 9028.8 CPM, and 3186 CPM.
3)
4)
Devices for air modulation are closed or plugged. Also check filters.
5)
6)
Vibration Problems
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1. Misalignment of drive components. 2. Poor foundations or mounting structure (resonances). 3. Foreign material attached to rotating components. 4. Damaged rotating components (bearings, shaft, fan, wheel, sheaves). 5. Broken, loose or missing setscrews. 6. Loose bolts. 7. Vibration transmitted by another source. 8. Water accumulating in airfoil blades. 9. Fan is operating in stall or unstable flow region.
UNIVERSITY OF PETROLEUM AND ENERGY STUDIES - DEHRADUN
Motor Problems
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1. Incorrect wiring.
2. Speed of fan too high. 3. Parts improperly installed - binding. 4. Bearings improperly lubricated. 5. WR2 capability of motor too low for application. 6. Protection devices may be improperly sized.
UNIVERSITY OF PETROLEUM AND ENERGY STUDIES - DEHRADUN
Conclusion
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Vibration
condition monitoring of rotating equipments is practical approaches to protection of these machines. Implementation of a condition monitoring program results in average maintenance savings of over 25%. Predict defects much in advance & behavior of the Machine Ensures safety, Ensures quality
References
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Operations & Maintenance Best Practices A Guide to Achieving Operational Efficiency U.S. Department of Energy Automation In Condition Based Maintenance Using Vibration Analysis, Thesis (M.Tech Maintenance Engg.)- Bankim Shikari Maintenance scheduling for mechanical equipment - Roger Cline Major process equipment Maintenance and Repair Heinz P Bloch, Fred K. Geitner. Gulf Publishing Company. www.maitenanceworld.com/articals/ Integrating Vibration, Motor Current, and Wear Particle Analysis with Machine Operating State for On-line Machinery Prognostics/Diagnostics Systems (MPROS) by Dana Martin and Joe Van Dyke, P.E. 1998 by DLI Engineering http://www.maintenanceresources.com/referencelibrary/ezine/chemclean.htm http://www.hofincons.com/operation.asp Maintenance Engineering and Management by Sunil Kumar Srivastva. S. Chand Publication - New Delhi Maintenance Engineering and Management by R C Mishra & K Pathak PHI Ltd.
23 THE KEY TO SUCCESS IS NOT TECHNOLOGY BUT AWARENESS OF VALUE, RESOURCES AND TIME
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