UNIVERSITY OF PETROLEUM AND ENERGY STUDIES

A Presentation On Major Project

CONDITION MONITORING OF CENTRIFUGAL FAN USING VIBRATION MESURMENT

Project Mentor Mr. P.K. Bahl Professor Emeritus COE,UPES
Presented By : Ankur Sharma (R220206001) Gaurav Joshi (R220206002)

Presentation Outline
2

Introduction

Maintenance Philosophies
Condition Monitoring Techniques Vibration Monitoring

Steps for a Vibration Monitoring

Problems with bearings and rotating equipment using

vibration analysis Conclusion References

UNIVERSITY OF PETROLEUM AND ENERGY STUDIES - DEHRADUN

Introduction
3

Condition monitoring is determining the health and condition of the

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

UNIVERSITY OF PETROLEUM AND ENERGY STUDIES - DEHRADUN

Application of Centrifugal Fans

4

Cement works - conveying/processing

Power stations
Process industry Air conveyors

Dust collection and material/particulate movement

Boiler and furnace ventilation Pneumatic conveying Deducting and exhaust fans

UNIVERSITY OF PETROLEUM AND ENERGY STUDIES - DEHRADUN

Maintenance Philosophies
5

Failure Based

Maintenance /Break down Maintenance Routine Maintenance/Preventive maintenance Design Out Maintenance Condition Based Maintenance

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Block Diagram for Condition Based Maintenance with CM

Condition Monitoring Techniques

6

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Condition Monitoring Techniques

7

Visual Inspection and Monitoring Temperature monitoring Performance monitoring

Vibration monitoring

Criticality Index
Selection equipment for Condition monitoring according

to purpose, redundancy , cost of repair

UNIVERSITY OF PETROLEUM AND ENERGY STUDIES - DEHRADUN

Vibration Monitoring
8

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

UNIVERSITY OF PETROLEUM AND ENERGY STUDIES - DEHRADUN

Vibration Monitoring
9

Displacement-is the distance moved by the measuring point to its

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.

Vibration Monitoring of the centrifugal pump

UNIVERSITY OF PETROLEUM AND ENERGY STUDIES - DEHRADUN

Typical Measurement System

10
Vibration machine or structure Vibration Transducer Signal Conditioning Display unit/Recorder

SPA for Vibration measurement

Data Analysis

Vibration Signature are characteristics of the machine.

A plot of amplitude and frequency of the vibrating component.

Advance warning, indication of failure.

UNIVERSITY OF PETROLEUM AND ENERGY STUDIES - DEHRADUN

Vibration Measuring Instruments

11

Accelerometer
Active transducer electromechanical transducer
When accelerometer is vibrated, the force to vibrate the mass is passed

through the piezoelectric discs

Electrical output signal proportional to acc. of mass Voltage or charge may be measured(charge = voltage * capacitance)

Accelerometer are user in most situations, particularly for structural and rotor support(bearing housing) vibration measurement

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Need of Vibration measurement

12

Demand

of economical design and high power density led to lighter structures and high operation speeds-led to highly stressed machinery

To reduce the down

time occurring to failure To maintain the reliability of the system

UNIVERSITY OF PETROLEUM AND ENERGY STUDIES - DEHRADUN

Steps for a Vibration Monitoring

13

List critical machines Establish acceptable levels of machinery vibration Determine each machine condition and bring to near normal level

Select periodic vibration check points

Select the interval for periodic vibration checks Start data recoding systems

Analysis of data and planning corrective actions

Training personnel

UNIVERSITY OF PETROLEUM AND ENERGY STUDIES - DEHRADUN

Condition monitoring (vibration) of pneumatic fan

Assembly: pneumatic fan Job: check vibration at fan and motor bearings.

14

Actual inspection date: Instrument: vibration analyser

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

Causes of the Vibration

15

Unbalance Misalignment Mechanical looseness Bent shaft

Bad rolling elements

bearing Damaged impellers Other defective components like bad pulleys/belts etc.

UNIVERSITY OF PETROLEUM AND ENERGY STUDIES - DEHRADUN

Finding Problems with Bearings and Rotating Equipment Using Vibration Analysis
16

Four Stages in Bearing Failure

The first stage (normal operation) appears at normal frequencies from about 1,200K to 3,600K CPM (cycles per minute) 2. bearing failure defects begin (30K-120K CPM) 3. In the third stage of failure, bearing defect frequencies and harmonics appear on the spectrum as Bearing defect frequency. At this time if you remove the bearing, you can see the defects in the rolling elements. 4. Stage four appears toward the end of bearing life Ball Bearing Vibration Data BPFO - Bearing Outer Race Frequency BPFI - Bearing Inner Race Frequency BSF - Ball Spin Frequency Rolling Elements
1.
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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:

Bearing running at 1800 RPM BPFO = .0497

.0497 X 1800 RPM = 89.46 Hz 89.46 Hz x 60 = 5367.6 CPM

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.

UNIVERSITY OF PETROLEUM AND ENERGY STUDIES - DEHRADUN

Various problems in Industrial Fans

18

Air Capacity Problems:

1)

Resistance of system not at design rating. If resistance is lower that

expected, both airflow and horsepower may be up. If resistance is

higher that anticipated, air volume will be down.
2)

Fan speed is not at design speed.

3)

Air density not at design values. Also check air performance

measurement techniques/procedures.

4)

Devices for air modulation are closed or plugged. Also check filters.

5)
6)

Wheel mounted improperly or is rotating in reverse.

Parts of system or fan have been damaged or need cleaning.
UNIVERSITY OF PETROLEUM AND ENERGY STUDIES - DEHRADUN

Vibration Problems
19

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
20

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
21

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

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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.

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23 THE KEY TO SUCCESS IS NOT TECHNOLOGY BUT AWARENESS OF VALUE, RESOURCES AND TIME

THANK YOU

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