Introduction to Portable

Vibration Analysis
Dieter Charle
BDM Portable Reliability Solutions | Europe
5/11/2015
 Emerson At-A-Glance 2015
US $24.5 Billion in Sales
Headquarters in Diversified global manufacturer Approximately
St. Louis, Missouri USA and technology provider 115,000 employees
worldwide

Manufacturing
220 manufacturing
No. 121 on 2014 Founded in 1890
and/or sales presence FORTUNE 500 list of
in more than locations America’s largest NYSE: EMR
150 countries around the world corporations

Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 2

 Emerson Invests in New Technology Development
to Meet Customer Needs
$805 million … Emerson’s investment in
Engineering & Development during 2015
1,900+ … patents awarded in 2015
to Emerson businesses

Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 3

 Emerson Global Presence 2015

Eastern Europe & Russia

Western Europe Sales $1.0 Billion
US & Canada Employees 9,000
Sales $3.8 Billion
Locations 15
Sales $11.2 Billion Employees 16,000
Employees 32,000 Locations 45
Locations 75
Asia
Sales $5.5 Billion
Employees 39,000
Latin America Middle East & Africa Locations 50
Sales $1.5 Billion Sales $1.5 Billion
Employees 18,000 Employees 1,000
Locations 30 Locations 5

Our Business Objective

To design, engineer, manufacture, sell and support
our products and solutions in every region of the world
Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 4
Note: Locations include manufacturing locations only.
 Our Industry Challenges
• Eliminate unplanned production shutdowns
– Minimize exposure – safer work environment
– Improved uptime
• Prioritize and plan maintenance actions
• Extend time between planned shutdowns
• Reduce inventory costs
• Increase availability and performance of assets
• Reduce preventive maintenance

Motors Pumps Gearboxes Turbines

Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 5
 Emerson’s Reliability Solutions

Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 6

 Portable Vibration Analysis – Industry Requirements
• Easy Routine Data Collection
Standard

• Get Faster Diagnoses

- Coherence case history
- Complex, hard to access machinery

• Advanced Diagnostics
- Detect misalignment during operation
- Live monitoring sleeve bearings
Advanced

- Commissioning smaller turbines

- Structural Analysis

Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 7

 Vibration Analysis
"Of all the parameters that can be measured non-intrusively in
industry today, the one containing the most information is the
vibration signature.“
- Art Crawford, Consultant / Author -

In one study, nearly two thirds of the

entire benefit from Machinery Health
Monitoring came from Vibration Analysis
- John E. Amos Power Station -

65% Vibration
Analysis

Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 8

 Vibration Analysis – Basic Principle
• Mechanical faults generate unique vibration
– Geometry of the machine Mechanical Defects detected with
• diameter of the shaft vibration analysis
Belt drive faults
• number of bearing elements Imbalance
Misalignment

Low
• Type of bearing elements Bent
Shaft
shaft
Rub
Looseness
Machine resonance
Bearing Defects including:

•cage defect
– Turning speed (e.g. RPM) •outer race defect
•inner race defect
•rolling element defect
Gear defects
Electrical faults

High
Cavitation
 Lubrication

Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 9

 Vibration from Mechanical Faults

Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 10

 Vibration from Mechanical Faults

Imbalance
1 x RPM

Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 11

 Vibration from Mechanical Faults

Blade Pass
4 x RPM

Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 12

 Vibration from Mechanical Faults

Gear Mesh
17 x RPM
Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 13
 Vibration from Mechanical Faults

Imbalance
1 x RPM

Blade Pass
4 x RPM

Gear Mesh
17 x RPM
Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 14
 How the Vibration Spectrum is Created

Amplitude
Tim
e
Amplitude

Amplitude
n cy
ue
eq
Tim Fr
e

Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 15

 Roller Bearing Faults
Four different bearing frequencies

Ball Spin Frequency

(BSF)

Fundamental Train
Frequency
(FTF)

Ball Pass Frequency

Inner Race
(BPFI)

Ball Pass Frequency

Outer Race
(BPFO)

Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 16

 How Bearing Faults Generate Vibration

Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 17

 One tool to WIN all challenges
Industry Requirements Modular Multi-Technology Platform
• Vibration Routes
Easy Routine Data Collection
• PeakVue Analysis

Standard
• 4-channel Analysis
Get Data Faster
• In-field Alarming
• Fault Frequencies
- Coherence case history • Parameter Trending
- Complex, hard to access machinery

• Cross Channel Analysis

Advanced Diagnostics
• Vibration Analysis/Troubleshooting
• AC Motor Rotor Bar Analysis

Advanced
- Detect misalignment during operation • 4-Plane Balancing
- Live monitoring sleeve bearings • Dual Orbit Plotting
- Commissioning smaller turbines • Transient Analysis
- Structural Analysis • ODS/Modal Analysis

Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 18

 Lower Cost = Earlier Warning = PeakVue Ea
sy
Progression of a Typical
Machine Problem
PeakVue Vibration

PeakVue is easy!
alert analysis Oil
analysis
Temperature
monitoring

Audible
noise • One single value to interpret
Equipment Health

PeakVue
Alert

• Earlier warning than any other

Spectrum
Analysis Hot to
touch

Overall
technology
Vibration
Equipment
Failure
• Indication of fault and severity
Time
Consequence

Time
Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 19
 Overall Vibration vs. PeakVue Ea
sy
0.5 12.5
Vibration Minimal Warning
in/s mm/s No
0.4 Warning! 9.0
0.15 / 3.7 Good

Vibration
FAULT
0.3 7.5
0.15 / 3.7 Good
ALERT
0.15 / 3.8 Good 0.2 5.0

0.16 / 4.0 Good? 2.5

0.1
0.18 / 4.5 OK?
0.0 0.0
0.30 / 7.5 Failure occurs!!!

Onset of

Bearing
Failure

Repair
Fault

After
PeakVue Early Warning with Severity 50
g’s

PeakVue (g’s)
FAULT
0 Good 40

an
10 Alert – Notify maintenance

Pl
30

To
20 Problem getting serious.

me
20
30 Near end of life

Ti
ALERT

40 Take action! Bearing failure imminent 10

50 Failure occurs!!!
Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 20 0
 PeakVue is Easy Ea
sy

Two Simple Rules:

1. Zero Principle 2. Rule of 10’s
• 10 – something’s happening
PeakVue on a good machine
is at or close to zero • 20 – something serious happening
• 40 – time to take action

Reliability 101 for Operators

PeakVue Interpretation
(g’s)

0 Good machine
10 Some Issue
20 Serious problem
40 Action Point
Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 21
 The magic behind Vibration Analysis Ea
sy

Raw measurement data - Waveform

Signal after band pass filter

Signal after rectifying

Enveloping registers (Demodulation)

Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 22

 The magic behind PeakVue
Vibration Analysis Ea
sy

Raw measurement data - Waveform

Signal after band pass filter

Signal after rectifying

PeakVue:
Peak Impact Detection registers
-Keep High Frequency Sample
-No Low Pass Filter

Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 23

 The magic behind PeakVue Ea
sy

Enveloping registers (Demodulation) Peak Impact Detection registers

Demodulation PeakVue
28 g’s
108g’s Amplitude Amplitude
1000 Hz
Bandwidth G’s Error G’s Error

1000 Hz 28 74% 108 0%

108g’s
8 g’s 200 Hz 8 92% 108 0%
200Hz

50 Hz 0.5 99% 108 0%

108g’s
50Hz >1 g

Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 24

 359 RPM

PeakVue Case Study – Outer Race Defect

Enveloping registers (Demodulation) Peak Impact Detection registers

Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 25

 Five Inputs / Eight Live Plots
Five Inputs:
 Channel 1
 Channel 2
 Channel 3
 Channel 4
 Plus Tachometer

 8 live plots

Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 26

 Patented Emerson Triax = Easy and Fast! Fa
st

Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 27

 Where to Use Triax or 4 Channels? Fa
st

• Everywhere in Route Mode

– Easier

– Faster

Example: Paper Plants (dryer section)

Ad
va
nc
ed
• Turbines Start-up (need to see phase info at both planes, so 4 Channels+Phase)
Ad
va
nc
e d
• All Advanced Applications Where Cross Channel Data is Needed
Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 28
 SpeedVue = Easy and Fast Fa
st

Measure rotating speed

without reflecting tape?

Yes, it is possible!

 Laser speed sensor

 Measure surface shape of shaft
 Calculates the rotation speed

Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 29

 In Field Analysis Fa
st
• Colored parameter alarms, provide
immediate indication of Machinery
Health
• See what parameter is in alarm and its
severity immediately at the point of
data collection
• Fault Frequencies help identify the
source of the vibration A A
M1H - RPM
May 2007 – July 2007

A A B B B B
A A A A B B B B

Fault
Fr eq

• Fault Frequencies help identify the

Fault
Nex t Prev
Frend
Tr eq Trend

source of the vibration

Am pl: 1 713.47 June 12 2007

Trend Fault Frequencies Parameter Alarms

Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 30
 Ad

Analysis Tools in the Field

va
nc
ed

• Analysis Experts are preconfigured so even a novice can use them.

• Allows troubleshooting tests to be performed while next to the
machine without making a return trip

Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 31

 Ad

Four Voltage Channels + Tachometer

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nc
ed

Dual Orbits!

Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 32

 Ad

Orbit Plots: Monitor 2 Sleeve Bearings

va
nc
ed

• True Orbit Plot

– Measure displacement
– 2x dual eddy current sensors @ 90° apart

Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 33

 Ad

Four Voltage Channels + Tachometer

va
nc
ed

and
Four Accelerometer
Channels + Tachometer

Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 34

 Ad
va
Transient analysis nc
ed

Analyze the detailed spectrum and

waveform by sliding of interest bar

Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 35

 Ad
va
Laser Shaft Alignment nc
ed

Use my analyzer tool for

simple & advanced Shaft Alignment?

Yes, it is possible!

Via Bleutooth Communication

Basic and Advanced Modes
- Add compensation factors
- Full or Partial Sweep

Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 36

 Ad
va
Single and Multi Plane Balancing nc
ed

Use my analyzer tool for simple &

advanced balancing jobs ?

Yes, it is possible!

 Laser position sensor + tape

 Acquire reference run data
Add or remove trail weights (plane 1, 2, etc)
View balance correction
Collect trim run data for corrected condition
Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 37
 Ad

Cross-Channel Phase
va
nc
ed

Check for Misalignment

– Measure across a coupling
– Check phase at running speed

Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 38

 Ad

Structural Analysis Options

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ed

• Operating Deflection Shape

– Performed while machine in operation
– Single frequency (typically running speed) measurement
– Can be performed with any CSI machinery analyzer
– Four channel is recommended
– Measures actual amplitude of deflection
– Shows how machine deflects in normal operation
• Modal Analysis
– Requires machine to be shut down
– Analysis across all frequencies
– Requires dual or four channel CSI 2140 for measurements
– With 4 channels: 1 channel is reference + triax
– Determines ratio of response to input, no absolute amplitudes
– Detailed model of machine stiffness, resonances, etc.

Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 39

 Ad
va
ODS on Piping nc
ed

• Triax sensor + ODS offers more

locations to collect data

• Due to Triax no more Software

interpolation required

Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 40

 Ad

Some other ODS-examples

va
nc
ed

Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 41

 Ad
va
Modal Analysis or Coherence Case History nc
ed

• Verify if vibration is related across points

• Reoccurring failure on paper machine
– Unusual vibration present
– Matched turning speed of pump below
• Coherence measurement
– proved that vibration was related
• Fixing pump operation
– solved paper machine problems

Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 42

 Ad

Resonance
va
nc
ed

• Natural frequencies are directional

• So, you need to measure in Horizontal, Vertical and Axial direction.
• With CSI 2140, all directions can be measured simultaneously
• For hammer impact tests, your hammer is channel 4

MOTOR

Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 43

 Ad

Impact Test Application

va
nc
ed

• Structural Analysis
– Identify resonances
– Measure stiffness
– Determine system response
MOTOR

– Modal analysis
• Use One Hammer and Three
Accelerometers
• Use One Hammer and One Triax
Sensor

Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 44

Ergonomics and
Features

CSI2140
The Portable Vibration Analyzer
of the future
 Screen & Keyboard

Automatic Backlight

Huge LCD Display

Backlit Keyboard

Touchscreen – glove compatible!

Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 46
 Thin Profile

3
6
5
4 9 mm
8
7
6
5
4
3
2
1
0

Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 47

 Built-in Stand

Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 48

 Comfortable New Strap

Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 49

 Communications

Ethernet
Bluetooth to
USB 2.0 accessories
Wi-Fi to AMS
Load Routes MachineryPort
Ethernet Manager
using USB
Memory Stick
Wi-Fi

Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 50

 Remove Wires to Increase Safety

>>>>>>>>>>>>>> >>>>>>>>>>>>>>

Customer
Customer Quote:
Quote:
“The
“The fact
fact is,
is, today
today none
none of
of my
my vibration
vibration techs
techs
would
would do do aa route
route without
without headphones.”
headphones.”

Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 51

 E-mail Route/Data Files
• Upload data to local PC with FREE
software
• E-mail, FTP, or copy across network
from remote location to database or
SME for archive and analysis

Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 52

 Li-ION Battery - Full 10 Hour Shift

8 Hr
24 Hr

Car Charger External Charger

Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 53
 Memory

1GB

Internal
External
32GB SD card

Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 54

 New Accessories
• CSI 2140 4-Channel Input Adapter
(Accel & Volts)

• Splitter Cables for 4-Channel

• Car Charger

• Bluetooth Wireless Headphones

• External Battery Charger

Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 55

Questions?
Dieter Charle
BDM Portable Reliability Solutions | Europe
Dieter.charle@emerson.com
+32 493 229 991