Condition Based

Maintenance
An Overview
PDC Engineering

What is CBM?

A maintenance strategy that is

based on maintenance being
carried out as and when the
equipment requires it.
Other strategies are:

Run to failure.
Hours or calendar based.

How do we know when to

do maintenance using
By taking measurements which will
CBM?

infer the condition of the machine

Measurement types include:

Vibration analysis
Infrared thermography
Passive ultrasound
Tribology
Process temperature, pressure etc

We want to monitor the

condition of our machinery

How do we start?
We carry out a
POTENTIAL FAILURE ANALYSIS

PFA for Press

anMainelectric
motor
Drive Motor PFA Tree
External
Manifestation

applicable Interval
parameters
Parameter The
Analysis
Set Up
In the last column we specify
Using
our
experience, we
This
example
will
require
for
detecting
spalled bearings
For example, spalled
We then
identify
how
that
some
of the
finer
detailsnow
to
The
detection
ofBrgspalled
Fmax =on
BPFIthe
x 8 specifics
We first
what
the
Dry/Marked
Bearing decide
Failure
High
frequency
Vibration
Demodulation
Spikesbased
@
defect
On Linedecide
a
measurement
on
are
velocity
spectrum
and
bearings
will lead
failure
to mechanism
will
show
Radial
bearings
resonance
@ bearing
(Ultra Sound)
frequencies
(20
dBG)
ensure
good,
bearings
should
bepractical
carried
whenincarrying
out the analysis
possible failuresdefect
could
beintervals
frequency
See
sect. 2.5 waveform
a
vibration
technology
time
GsG acceleration
a bearing failure
itself as something
we
can
measure
Time
failure
detection
out
continually
(On-Line) On Line = 3 revs
Peaks in waveform
Waveform
Base Cause

Failure Type

Spalled
bearings

Bearing Failure

Harmonics of bearing
defect frequencies

Technology

Vibration

Velocity

Spikes @ Brg defect

freqys. & harmonics
and/or sidebands.
See sct. 2.5

On Line

Fmax = BPFI x 8
(higher if not using
resonance parameter)
Radial

Time
Waveform

Peaks @ 12 G (roller)
7 G (ball brg)

On Line

= 3 revs
G acceleration

Misalignment

Bearing Failure/
Shaft Failure

High axial vibration

Vibration

Velocity

Multiples of run speed

axial > radial

On Line

Fmax = 10 x rpm
Axial

Looseness

Bearing Failure/
Shaft Failure/
Structural Failure

Run speed harmonics

& subharmonics

Vibration

Velocity

Multiples of run speed

up to 15x. Possible
sub-harmonics

On Line

Fmax = 10 x rpm
Vertical

Reduced Power
Motor Burnout

Vibration @ SCR Frqys

Vibration

Velocity

Changes in SCR temps.

Thermography

Bad S.C.R.s

Winding
defects

Rotor
defects

On Line

Thermal Image

240 Hz, 1/3 DC pulse,

s/band on DC(Sect.2.5)
Bad SCR is colder

6 month

Fmax = 120 kcpm

Drive End
Compare SCR to SCR

Different current /
Current Draw
input phase
Stator temp. rise/
Thermography
Uneven temp. distribution

Amps

Unbalanced supply

6 month

Compare phase to phase

Thermal image
(spot temp)

Hot spot on stator

6 month

1 baseline

Earth current leakage

Insulation test

Megger

Should be > 1.5 M

6 month

Motor de-energized

Rotor failure

Line frequency +
sidebands

Motor load
Motor current
current analysis frequency

6 month

Press idling

Motor burnout

Vibration @ rotor bar

pass frequency

Vibration

Sidebands of slip x No.

of poles around 60 Hz
(Sect. 2.2)
Sidebands of 1x
(Sect 2.2)

Motor burnout

Velocity

On Line

Fmax = RBPF x 3
Radial
c. Ron Frend - PreDiCon

100 HP AC Motor PFA Tree

Base Cause

Failure Type

Dry/Marked
bearings

Bearing Failure

Spalled
bearings

Bearing Failure

Misalignment

Bearing Failure/
Shaft Failure

Looseness

Bearing Failure/
Shaft Failure/
Structural Failure

Winding
defects

Motor burnout

Rotor
defects

Bearing failure

Motor burnout

External
Manifestation

Technology

Parameter

Interval

Detail

100 HP AC Motor PFA Tree

External
Manifestation

Base Cause

Failure Type

Dry/Marked
bearings

Bearing Failure

High frequency resonance

@ bearing defect
frequency intervals

Spalled
bearings

Bearing Failure

Harmonics of bearing
defect frequencies

Misalignment

Bearing Failure/
Shaft Failure

High axial vibration

Looseness

Bearing Failure/
Shaft Failure/
Structural Failure

Run speed harmonics

& subharmonics

Winding
defects

Motor burnout

Stator temp. rise/

Uneven temp. distribution
Earth current leakage

Rotor
defects

Bearing failure

Line frequency +
sidebands

Motor burnout

Vibration @ rotor bar

pass frequency

Technology

Parameter

Interval

Detail

100 HP AC Motor PFA Tree

Base Cause

Failure Type

Dry/Marked
bearings

Bearing Failure

External
Manifestation

High frequency resonance

@ bearing defect
frequency intervals

Technology

Parameter

Vibration

Enveloping
(HFD/B)
(Shock Pulse)
(Ultra Sound)
Time Waveform

Spalled
bearings

Bearing Failure

Harmonics of bearing
defect frequencies

Vibration

Velocity

Time Waveform
Misalignment

Bearing Failure/
Shaft Failure

High axial vibration

Vibration

Velocity

Looseness

Bearing Failure/
Shaft Failure/
Structural Failure

Run speed harmonics

& subharmonics

Vibration

Velocity

Winding
defects

Motor burnout

Stator temp. rise/

Uneven temp. distribution

Thermography

Thermal image
(spot temp)

Earth current leakage

Insulation test

Megger

Bearing failure

Line frequency +
sidebands

Motor load
current analysis

Motor current
frequency

Motor burnout

Vibration @ rotor bar

pass frequency

Rotor
defects

Vibration

Velocity

Interval

Detail

100 HP AC Motor PFA Tree

Base Cause

Failure Type

Dry/Marked
bearings

Bearing Failure

Spalled
bearings

Bearing Failure

External
Manifestation

High frequency resonance

@ bearing defect
frequency intervals

Harmonics of bearing
defect frequencies

Technology

Parameter

Interval

Vibration

Enveloping
(HFD/B)
(Shock Pulse)
(Ultra Sound)

1 month

Time Waveform

1 month

Velocity

1 month

Time Waveform

1 month

Vibration

Misalignment

Bearing Failure/
Shaft Failure

High axial vibration

Vibration

Velocity

3 month

Looseness

Bearing Failure/
Shaft Failure/
Structural Failure

Run speed harmonics

& subharmonics

Vibration

Velocity

1 month

Winding
defects

Motor burnout

Stator temp. rise/

Uneven temp. distribution

Thermography

Thermal image
(spot temp)

6 month

Earth current leakage

Insulation test

Megger

6 month

Bearing failure

Line frequency +
sidebands

Motor load
current analysis

Motor current
frequency

6 month

Motor burnout

Vibration @ rotor bar

pass frequency

Velocity

3 month

Rotor
defects

Vibration

Detail

100 HP AC Motor PFA Tree

Base Cause

Failure Type

Dry/Marked
bearings

Bearing Failure

Spalled
bearings

Bearing Failure

External
Manifestation

High frequency resonance

@ bearing defect
frequency intervals

Harmonics of bearing
defect frequencies

Technology

Parameter

Interval

Detail

Vibration

Enveloping
(HFD/B)
(Shock Pulse)
(Ultra Sound)

1 month

Fmax = BPFI x 3
Radial
G acceleration

Time Waveform

1 month

= 3 revs

Velocity

1 month

Fmax = BPFI x 3
(higher if not using
resonance parameter)

Vibration

Radial
Time Waveform

1 month

= 3 revs
G acceleration

Misalignment

Bearing Failure/
Shaft Failure

High axial vibration

Vibration

Velocity

3 month

Fmax = 4 x
Axial

Looseness

Bearing Failure/
Shaft Failure/
Structural Failure

Run speed harmonics

& subharmonics

Vibration

Velocity

1 month

Fmax = 4 x
Vertical

Winding
defects

Motor burnout

Stator temp. rise/

Uneven temp. distribution

Thermography

Thermal image
(spot temp)

6 month

1 baseline

Earth current leakage

Insulation test

Megger

6 month

Motor de-energised

Bearing failure

Line frequency +
sidebands

Motor load
current analysis

Motor current
frequency

6 month

Motor running
> 1/2 load steady

Motor burnout

Vibration @ rotor bar

pass frequency

Velocity

3 month

Fmax = RBPF x 3
Radial

Rotor
defects

Vibration

How do I start?

First define your PFAs

Decide on applicable technologies

Decide on measurement intervals
Decide on measurement strategy

Maintain copies of PFAs for ISO

9002 audit compliance

Applicable Technologies

Vibration Analysis
Infrared Thermography
Passive Ultrasound
Tribology

Vibration Analysis

On Line or Off Line?

How long is the failure mechanism?

Will the machine always run at measurement
time?
Does the machine run under consistent
conditions?
Is access safe?
Is access convenient?

Rule of thumb

Use on-line for process critical or high capital

cost equipment
Use off line for spared or non-critical
equipment

The Failure Mechanism

Example:

A bearing on a large slow moving fan may last for

a year after the onset of lubrication failure.
A bearing on a pump may only last 2 days
depending on load, speed, alignment, initial
lubrication etc.

Remember:

Vibration will only detect defects that exhibit a

measurable difference prior to failure.
Vibration WILL NOT detect fatigue or stress failures
in advance as there is no external change to
influence the vibration parameters.

Run Conditions

Modern on-line systems can store data

in separate locations for different
running conditions (load, speed etc).
On-line systems should not store data
when the equipment is not running.
Remember the value of a vibration
analysis system is in the DATA NOT the
equipment. On-line gives full value
continually.

Vibration examples

Mill gearboxes
Lauter Tun drives
General examples

Mill Crankshaft Gearboxes

Mill #2 Drive
Gearboxes
Top/Middle/Bottom
8th of July 1999 at
8:16 am

Lauter Tun Gearboxes

Samlesbury Brewery
Measurement Event Note (01/02/2002 08:50:57)
Output shaft rising

O/All 0.803 mm/s rms

0.7

Output shaft rising at time of reading

0.6

Lauter Tun 1 (red)

Lauter Tun 2 (blue)
Output Shaft
31st January 2002

0.5

mm/s rms

0.4

0.3

0.2

0.1

-0.1
0

Lauter Tun 1
Lauter Tun 2

1,000

Gbox Output Top

Gbox Output Top

2,000

Tangential
Tangential

3,000
CPM

Vel Freq 6000 CPM

Vel Freq 6000 CPM

4,000

31/01/2002 15:40:23
31/01/2002 14:48:48

5,000

O/All 0.803 mm/s rms

O/All 0.09 mm/s rms

6,000

<set RPM>
<set RPM>

Output shaft ris ...

<add note>

General Examples
Tank - Soplador de Igualacin B302C
Sopl B302C-AVV Motor LL vertical velocidad

22
20

14

Imbalance

12
10
8

Route Spectrum
05-MAY-98 13:23
OVRALL= 11.14 V-DG
RMS = 11.08
CARGA = 100.0
RPM = 1786.
RPS = 29.77
Fault Limit

Looseness

4
2
0

0
0

30

60

90

120

150

180

210

240

20

40

Frequency in kCPM

60

80

Frequency in kCPM
Tank - Soplador de Igualacin B302C
Sopl B302C-AVV Motor LL vertical velocidad

80

W aveform Display
23-MAR-98 13:45

60

Acceleration in G-s

RMS Velocityin mm/Sec

16

R M S V e lo c ity in m m /S e c

OVRALL= 18.65 V-DG

RMS = 18.54
CARGA = 100.0
RPM = 3583.
RPS = 59.71
Alert Limit

18

Fosf - Bomba #3 Circulacion Etapa#6

PFO6-4BV30-AVH Motor LL Horizontal Velocidad

10

Route Spectrum
23-MAR-98 13:45

40

PK = 24.00
CARGA = 100.0
RPM = 3583.
RPS = 59.71

20

PK(+) = 64.51
PK(-) = 42.17
CRESTF= 3.80
FAULT
ALERT

ALERT
FAULT
-20

-40

-60
0

Bad Bearings
4

10
Time in mSecs

12

14

16

18

20

Time:
Ampl:

1.094
64.52

100

120

Freq: 114.15
Ordr: 63.91
Spec: .00305

Infrared Thermography

Non contact
Non intrusive
Radiometric capability
Images stored for history

Infrared Thermography
Electrical Example
74.1C
70

60

Terminal: 74.6C

50

40
39.1C

Boiler Primary 46B/75

20th October 2000

Infrared Thermography
Mechanical Example
66.6C
60
Mtr D/E Brg: 66.9C
Mtr Body: 50.1C
Pump Brgs: 35.4C

40

20

8.3C

Brine Fixed Speed Pump 53C/007

20th October 2000

Passive Ultrasound

Trouble shooting
Bearings
Air leaks
Hydraulic valves
Steam traps

Passive Ultrasound
Ts6_good.wav

Ultrasound
recording of
a good
bearing

Ts2_bad.wav

Ultrasound
recording of
a bad
bearing

Tribology

Very early warning of defects

Most useful in hydraulic systems
ISO cleanliness or SOAP

Spectrographic Oil Analysis Progamme

Oil Analysis SOAP Trend

Iron
Copper
Viscosity
Oxidation
Silicon
Lead
Oil Rating
Changed
Filters
Temp(fluid)
Temp(pmp)

Alarms
13.0538793
8.833227979

15/09/1994
11
8
266
1
1
0
Sat

05/11/1994
12
8
268.4
0
0
0
Sat

01/12/1994
7
5
272.5
0
0
0
Sat

26/01/1995
10
5
273.2
0
0
0
Sat

14/04/1995
10
6
273.5
1
1
0
Sat

16/05/1995
8
5
274
0
0
0
Sat

07/07/1995
8
6
275
1
0
0
Sat

17/08/1995
11
8
275.3
1
0
1
Sat

06/10/1995
6
5
272.6
1
0
0
Sat

16/11/1995
9
170
274.7
0
0
17

26/12/1995
12
186
281.2
2
0
20

19/01/1996
4
47
275.8
0
0
4
Sat

05/01/1996
79
95
450 A OIL ANALYSIS

200
180
PARTS PER MILLION

160
140
120
100
80

Iron

60

Copper

40
20
0
Alarms

15/09/1994

05/11/1994

01/12/1994

26/01/1995

14/04/1995

16/05/1995

07/07/1995

17/08/1995

06/10/1995

16/11/1995

26/12/1995

19/01/1996

Ferrography

Microscopic analysis of oil samples

ISO Cleanliness Codes

CLEANLINESS LEVEL CORRELATION TABLE
Particles NAS 1638
per ml>10
(1964)
ISO CODE microns
(1963)
SAE Level

21/18

4500

12

20/18

2400

20/17

2300

11

20/16

1400

19/16

1200

10

18/15

580

17/14

280

Approximate NewOil

16/13

140

15/12

70

14/12

40

14/11

35

13/10

14

12/09

11/08

10/08

10/07

2.3

10/06

1.4

09/06

1.2

08/05

0.6

Normal Operating Cleanliness

Levels (unfiltered oil)

Critical Cleanliness
Range (critical
hydraulic units)

Particle count testing provides a

determination of the number of
particulates in a specific size range
using the International Standards
Organization (ISO) Cleanliness
Code, ISO 4406. An ISO Code is
created by selecting three ISO range
numbers that correspond to the
number of particles in a milliliter of
fluid greater than 2, 5, and 15
microns, respectively.

In-House or Outsource?

This must be your decision based

on:

Cost
Available manpower
Training commitment
Ownership strategy

Define A Project

Whichever method you choose,

treat the installation of CBM as a
maintenance project
Define targets, milestones and
resources
Measure your progress and report
regularly

The Project Timeline

End Points

Be consistent
Have a clearly defined reporting
strategy
Report your cost savings regularly
IF IT ISNT SAVING YOU MONEY ITS
NOT WORTH DOING