Implementation of a Predictive

Maintenance System

zz
zz
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Machine
Machinetypes
types
Potential
PotentialFailure
FailureModes
ModesPFM
PFM
Fault
detection
methods
for
Fault detection methods forbest
best
covering
covering PFM
PFMof
ofmachines
machines
Transducer
Transducermounting
mounting
Repeatable
measurements
Repeatable measurements

Potential Failure Modes

(PFM)

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zz
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Different
Different machines
machineshave
havedifferent
differentPotential
PotentialFailure
FailureModes
Modes
Design
parameters
such
as
bearing
construction
Design parameters such as bearing constructionand
andspeed
speed
influences
influenceson
onPFM
PFM
AAPredictive
PredictiveMaintenance
Maintenancesystem
systemshould
shouldbe
bedesigned
designedtotoDetect
Detect
aaMaximum
number
of
PFMs
Maximum number of PFMs

Page 1

Classification Of Machines
Driving
Machines

Intermediate

Electric Motors
Engines
Diesel
Gas

Turbines
Steam
Gas
Water
Hydraulic
Wind

Couplings
Flexible
Fixed
Cardan

Gears
Helical
Straight
Planetary

Belts

Driven Machines
Pumps
Compressors
Generators
Material
Transportation
Paper Machines
Transport Rollers

Other
Steel Roller
Ship Propellers
Vehicles
etc.

Types of
Bearings

Journal
JournalBearings
Bearings

Stationary
StationarySignals
Signals
Relative
RelativeLow
LowFrequency
Frequency
Displacement
Displacementtransducer
transducer

Rolling
RollingElement
ElementBearings
Bearings
Modulated
ModulatedRandom
RandomNoise
Noise
Pulsating
signals
Pulsating signals
High
HighFrequency
Frequency
Accelerometers
Accelerometers

Page 2

Machine Signal Types

Semi Static
Shaft Position

Harmonic
Imbalance
Misalignment
1X

Modulated

2X

200Hz

Torsional Load
Tooth Fatigue
Eccentricity
1X

5 kHz

1X

10 kHz

1X

10 kHz

Random
Lubrication Problems
Rolling Element (RE)
Bearing Mounting defect
Flow Exited

Pulsed
RE Bearing Wear
Rubs
Blade Damage, fouling
Surge, Cavitation,
Local Tooth Defects

Time

Frequency

CPB The Detection Tool

Constant Percentage Bandwidth Spectrum
Best tools for Detection of Potential Failure Modes

Log
Amplitude

Low frequency

High frequency

High resolution
(Characteristic
components)

Coarse resolution
Sideband families
resonances
Impulse response

Log
Frequency

Page 3

Basic Principles of a Predictive

Maintenance System

zz To
ToListen
Listenfor
forchanges
changes in
in

machinery.
machinery.

zz In
Inorder
orderto
tofind
findthe
the

changes
changes the
the
measurements
measurementsmust
mustbe
be
repeatable
repeatable over
over time.
time.

Repeatable
Measurement

zz

< 12 - 25%

Detection
Detectionrange
rangefor
foraafault
faultisis
66--88dB
dB(2
(2--2,5
2,5times)
times)

Measurements
Measurementsmust
mustbe
be
repeated
repeatedwithin
within1-2
1-2dB
dB
(12
(12-25%)
-25%)

zz

Data

2526

Collec
tor B
7/6-'89
F4

F3

F2
Next

7
4
1

.
E

Check

On/Off

Repeatability
RepeatabilityTest.
Test.
Perform
Performthe
thesame
same
measurement
measurementtwice.
twice.

Page 4

Measur

8
5
2

Adequate
Adequatetrending
trending
Statistical
Statisticalvariations
variations
zz

Brel
Collec & Kj
r
tor
Type

F5

Enter

Previou
s

9
6
3

0
Del

F1

Sources of Measurement
Uncertainty
Data

Brel
& Kj
Collec
r
tor
Type
2526

K
Collec
tor

B
7/6-'89

F5

F4
F3

F2
F1

Enter
Next

Previou
s

Measur

7
5

2
-

1
.
E

0
Check
Del

On/Off

zz
zz
zz
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Random
RandomVariations
Variationsatatthe
the
machine
machine
Poor
PoorMounting
Mounting
Cable
CableNoise
Noise
To
To low
lowaveraging
averagingtime
time
to
take
account
to take accountofofmachine
machine
variations
variations
to
totake
takeaccount
accountofof
measurement
measurementuncertainty
uncertainty

Mounting of Accelerometers
zz

The
Thecontact
contactbetween
between
accelerometer
accelerometer
and
andmagnet
magnetisisCritical
Critical
Apply
ApplySilicon
SiliconGrease
Grease
or
or
Cyano
CyanoAcrylic
Acryliclock
locktight
tight

Stud
Studmounting
mountingbest,
best,but
but
impractical.
impractical.

zz

Hand
Handheld
heldprobes
probesare
areeasy
easybut
but
Variations
Variationsup
uptoto55dB
dBinin
frequency
frequencyrange
rangebelow
below11kHz
kHz
No
Norepeatability
repeatabilityabove
above22kHz.
kHz.

zz

Grinding
Grindingofofsurface
surfaceisis
recommended
recommendedbut
but
Difficult
Difficulttotoobtain
obtainrequired
required
flatness.
flatness.
Expensive
Expensiveininmanpower
manpower
Explosive
Explosiverequirements.
requirements.

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Thickness
>3 mm

Epoxy
Epoxygluing
gluingof
ofcorrosive
corrosiveresting
resting
magnetic
magneticmetal
metalplates
plates
recommended
recommended
Easy
Easytotoapply
apply

Magnetic
MagneticStainless
StainlessSteel
Steel
AISI
AISI430F
430F
Mounting
MountingPlate
Plate

Page 5

To
Tobe
beglued
gluedon
oncleaned
cleaned unpainted
unpainted
Machine
surface
Machine surface

Cable
Considerations.

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zz
zz
zz

Charge
Chargesignals
signalsare
areprone
pronetotoTribo
Tribo
electric
electricnoise
noisedue
duetoto low
lowfrequency
frequency
wind
movement
wind movement
Built
Builtininpreamplifiers
preamplifiers(Delta
(DeltaTron)
Tron)will
will
reduce
reducethis
this effect.
effect.
Cable
Cableconnection
connectiontotoaccelerometer
accelerometer
can
canbe
becritical.
critical.
Low
Lowfrequency
frequencynoise
noisecan
canalso
alsobe
be
induced
inducedininaccelerometers
accelerometersdue
duetoto
thermal
thermalgradients.
gradients.

-- - ++
-+ -

Bending
BendingCable
CableGive
Give
changed
changedinductance
inductance
false
false vibration
vibration
readings
readingsin
inthe
the
low
frequency
low frequency
range
range

Analysis Band
Width
33Periods
Periods
of
ofVibration
Vibration

Lower
LowerFrequency
Frequency
Longer
LongerMeasurement
Measurement
time
time

Page 6

Measurement
time
Harmonic
Harmonicsignals
signalscan
canbe
be
measured
measuredininshort
shorttime
time
zz Random
Randomand
andPulsed
Pulsedsignals
signals
need
longer
time
need longer time
zz For
ForFFT
FFTspectra
spectraCC==11pr.
pr.
average.
average.
zz With
WithDigital
DigitalFiltered
FilteredCPB
CPB
Adequate
measurement
Adequate measurementtime
time
can
canbe
beset
setup.
up.
zz

B
B ** TT == C
C

BB==Highest
Highestresolution
resolutionofofAnalysis
Analysis
TT==The
TheShortest
Shortestmeasurement
measurementtime
time
CC==Constant.
Constant.

Theoretical
Theoretical

CC==33for
forHarmonic
HarmonicSignals
Signals
CC==30
30For
ForRandom
RandomSignals
Signals

Typical
Typicalaveraging
averagingtime:
time:

10
10sec
secfor
for6%
6%
55sec
secfor
for23
23%
%
20
20sec.
sec.for
forslow
slowrunning
runningmachines.
machines.

In
InPractice
Practice

CC==55for
forHarmonic
HarmonicSignals
Signals
CC==100
100For
ForRandom
RandomSignals
Signals

Number of Monitor Points

pr. Machine
1.1.
The
TheCustomer
Customeris
is
always
alwaysright
right
Accept
Acceptlocal
local

44
Monitoring
MonitoringPoints
PointsPlaced
Placedin
in
between
betweenBearing
Bearingwill
willcover
cover
both
bothbearings
bearingson
onmachines
machines
<<100
kW
100 kW
(Depending
(Dependingon
onConstruction
Constructionetc.)
etc.)

Standards
Standards

2.2.
Reduce
Reducethe
the
number
numberof
of
monitoring
monitoringpoints
points
to
toaaminimum
minimum

Meas.
Meas.
Point
Point

3.
3.
Small
SmallMachines
Machines
may
maybe
bemonitored
monitored
by
byone
onesingle
single
measurement
measurementpoint
point
per
perMachine.
Machine.

Page 7

Meas.
Meas.
Point
Point

Monitoring of big machines

2nd
2ndBest
Best

Best
Bestpoint
point
for
formeasurements
measurements

One
OneRadial
RadialMonitoring
Monitoring
Point
Pointpr.
pr.Bearing
Bearing
Measurement
MeasurementPoint
Point

Data

Brel
Collec & Kj
r
tor
Type

2526

K
Collec
tor B
7/6-'89
F5

F4

F3

F2

Enter

F1

Next

to
tobe
beplaced
placedwith
withrigid
rigid
connection
connectionto
tobearing
bearing

Previou
s

Check

On/Off

5
4

.
E

Measur

6
3
-

0
Del

Avoid
AvoidBearing
Bearing
covers
covers

One
OneAxial
AxialMonitoring
Monitoring
Point
Pointpr.
pr.Bearing
Bearing
Measurement
MeasurementPoint
Point

close
closeto
toaxial
axialsupport
support
bearing
bearing

Axial
Axial&&Radial
Radial
Bearing
Bearing

Frequency of
Monitoring

Normal Freq.
Range for Fault
Detection

zz

zz

2.5
2
1.5
1

1/3 - 1/4
of RPM

61

41

51

31

21

11

0.5

10 -14
k Hz

zz

Page 8

For
Fornormal
normalHigh
HighSpeed
Speed
machinery
machinery(>500
(>500RPM)
RPM)
Lower
LowerFrequency
Frequency0.25
0.25
%
%--0.33
0.33%
%or
orRPM
RPM
For
Forlow
lowfrequency
frequency
machinery
machinery
Lower
Lowerfrequency
frequency<<
RPM
RPMififpossible.
possible.
Higher
Higherfrequency
frequency
For
ForRolling
Rollingelement
element
Bearings
Bearings 10
10--14
14kHz
kHz
depending
dependingon
on
mounting
mountingtechnique
technique
Other
OtherMachines:
Machines:
up
uptoto10
10kHz
kHz

Measurement
Parameter

zz
zz

Acceleration

zz
zz
zz

Velocity

zz

Find
Findthe
theflattest
flattestspectrum
spectrum
Normally
velocity
Normally velocity
For
Forvery
veryslow
slowrunning
runningmachine
machine
(<
600
RPM)
acceleration
(< 600 RPM) accelerationisis
preferred.
preferred.
For
ForHigh
Highfrequency
frequencydiagnostics
diagnostics
use
useacceleration
acceleration
Always
Alwaysuse
useacceleration
accelerationfor
for
Envelope
Envelopeanalysis.
analysis.

Displacement

Measurement
Time

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zz

High
Highspeed
speedmachinery
machineryonce
oncepr.
pr.month
month
Low
Speed
machinery
once
every
Low Speed machinery once every33month.
month.

Page 9

Building Up a Predictive
maintenance system.

zz

Start
Startwith
withfew
fewmachines.
machines.
Misunderstandings,
Misunderstandings,mal
malpractices
practicesand
andmeasurement
measurementsetups
setupsare
areeasily
easily
changed
changedby
bylearning.
learning.

zz
zz

Dont
Dontexpect
expectsuccess
successwithin
withinthe
thefirst
firsthalf
halfyear.
year.
Training
should
be
repeated.
Training should be repeated.

Page 10