Machine Condition Monitoring and Fault Diagnostics
Chris K Mechefske
September 4, 2008
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Course Overview
Introduction to Machine Condition Monitoring and Condition Based Maintenance Basics of Mechanical Vibrations Vibration Transducers Vibration Signal Measurement and Display Machine Vibration Standards and Acceptance Limits (Condition Monitoring) Vibration Signal Frequency Analysis (FFT)
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Course Overview
Machinery Vibration Testing and Trouble Shooting Fault Diagnostics Based on Forcing Functions Fault Diagnostics Based on Specific Machine Components Fault Diagnostics Based on Specific Machine Type Automatic Diagnostic Techniques Non-Vibration Based Machine Condition Monitoring and Fault Diagnosis Methods
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Current Topic
Introduction to Machine Condition Monitoring and Condition Based Maintenance Basics of Mechanical Vibrations Vibration Transducers Vibration Signal Measurement and Display Machine Vibration Standards and Acceptance Limits (Condition Monitoring) Vibration Signal Frequency Analysis (FFT)
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Vibration Standards and Acceptance Limits
Standards are documented agreements containing technical specifications or other precise criteria to be used consistently as rules, guidelines, or definitions of characteristics, to ensure that materials, products, processes and services are fit for their purpose.
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Vibration Standards and Acceptance Limits
A good standard - represents consensus of opinion - is easy to understand and use - contains no ambiguities or loopholes
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Vibration Standards and Acceptance Limits
ISO Standards are developed according to the principles of Consensus amongst participants Industry-wide participation Voluntary participation
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Vibration Standards and Acceptance Limits
IEC - International Electrical Commission product oriented. ANSI - American National Standards Institute non government Domestic Government Agencies Defence Departments
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Vibration Standards and Acceptance Limits
ISO - Organisation for International Standards Technology Oriented National Standards bodies from 130 countries (Standards Council of Canada) TC (Technical Committee) 108 Mechanical Vibration and Shock SC (Sub-Committee) 5 - Condition Monitoring and Diagnostics of Machines
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Vibration Standards and Acceptance Limits
ISO TC 108 Mechanical Vibration and Shock SC 1 - Balancing SC 2 - Measurement and Evaluation SC 3 - Measuring Instruments SC 4 - Human exposure SC 5 - Condition Monitoring SC 6 - Vibration Generating Systems
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Vibration Standards and Acceptance Limits
ISO TC 108 Mechanical Vibration and Shock Scope (general): Standardization in the field of mechanical vibration and shock, and condition monitoring and diagnostics of machines.
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Vibration Standards and Acceptance Limits
ISO TC 108 Mechanical Vibration and Shock Scope (detail):
- terminology - excitation - vibration control - human exposure - measurement and calibration - test methods - condition monitoring & diagnostics
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Vibration Standards and Acceptance Limits
ISO TC 108 SC 5 WG1 Terminology WG2 Data Interpretation and Diagnostics Techniques WG3 Performance Monitoring and Diagnostics WG4 Tribology WG5 Prognostics WG6 Formats and Methods for Presenting Data WG7 Training and Certification WG 8 M&D of machines WG10 M&D of electrical equipment WG11 Thermal Imaging
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Vibration Standards and Acceptance Limits
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Vibration Standards and Acceptance Limits
ISO 7919 Series 7919-1:1996 7919-2: 2001 7919-3: 1996 7919-4: 1996 7919-5: 1997
Mechanical vibration of non-reciprocating machines - Measurement on rotating shafts and evaluation criteria Part 1: General Guidelines Part 2: Land-based steam turbines and generators in excess of 50 MW with normal operating speeds of 1500 r/min, 1800 r/min, 3000 r/min and 3600 r/min Part 3: Coupled industrial machines Part 4: Gas turbine sets Part 5: Machines set in hydraulic power generating and pumping plants
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Vibration Standards and Acceptance Limits
ISO 10816 Series 10816-1: 1995 10816-2: 2001 10816-3: 1998 10816-4: 1998 10816-5: 2000 10816-6: 1995 10816-7
Mechanical vibration - Evaluation of machine vibration by measurements on non-rotating parts Part 1: General Guidelines Part 2: Land-based steam turbines and generators in excess of 50 MW with normal operating speeds of 1500 r/min, 1800 r/min, 3000 r/min and 3600 r/min Part 3: Industrial machines with normal power above 15kW and nominal speeds between 120 r/min and 15000 r/min when measured in situ Part 4: Gas turbine sets excluding aircraft derivatives Part 5: Machines set in hydraulic power generating and pumping plants Part 6: Reciprocating machines with power ratings above 100 kW Part 7: Rotodynamic pumps for industrial application
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Vibration Standards and Acceptance Limits
Standards Based on Type of Machinery 1. Reciprocating Machinery both rotating & reciprocating components engines, compressors, pumps 2. Rotating Machinery - Rigid Rotors electric motors, single stage pumps, slow speed pumps measure vibration from housing, vibration transmitted well through housing
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Standards Based on Machinery Type
3. Rotating Machinery - Flexible Rotors large steam turbines, multistage pumps, compressors critical speeds different modes of vibration at different speeds vibration not transmitted well through bearings must measure vibration of shaft directly 4. Rotating Machinery - Quasi-rigid Rotors low pressure steam turbines, axial flow compressors, fans some vibration gets through bearings
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Vibration Standards and Acceptance Limits
Machine High Pressure Turbine Low Pressure Turbine Large Generator High Pressure Centrifugal Compressor Large Fan Small Fan & Pump Vertical Pump Large Steam Turbine Generator Set
Dynamic Stiffness Ratio, 5 1.5 1.5 5 2/3 1/3 1/10 1.5 to 3
ISO 10816 (pedestal) Moderate Moderate Moderate Not Good Good Good Good Moderate
ISO 7919 (shaft) Good Good Good Good Moderate Moderate Not Good Good
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Vibration Standards and Acceptance Limits
Standards Based on Vibration Severity Standards depend on: frequency range of vibration (speed of machinery) type & size of machine service expected mounting system effect of machinery vibration on surroundings
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Standards Based on Machinery Type
A good, B Acceptable, C Monitor closely, D - Unacceptable
Vibration Severity ISO IS 2372
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Vibration Standards and Acceptance Limits
Class I individual components, integrally connected with complete machine (electric motors up to 15 kiloWatts) Class II Medium sized machines (15 75 kiloWatt electric motors) Class III Large prime movers on heavy, rigid foundations Class IV Large prime movers on relatively soft, lightweight foundations
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Vibration Standards and Acceptance Limits
R.m.s. vibration velocity mm/sec 0,28 0,45 0,71 1,12 1,8 2,8 4,5 7,1 11,2 18 28 45
up to 15 kW Class I
15 to 75 kW Class II
> 75 kW (rigid) Class III
> 75 kW (soft) Class IV
A B
B C C C D C D D D B B
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Standards Based on Machinery Type
Vibration Severity ISO IS 3945
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Standards Based on Vibration Severity
Small - medium sized machines 600 - 12,000 r.p.m. shaft speeds rigid rotors velocity amplitudes highest broad-band root-mean-square value in frequency range 10-1000 Hz. triaxial bearing cap vibration measurements
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Standards Based on Vibration Severity
Large sized machines 600 - 1,200 r.p.m. shaft speeds rigid support - machine fundamental resonant frequency is above main excitation frequency flexible support - machine fundamental resonant frequency is below main excitation frequency
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Standards Based on Vibration Severity
Electric Motors size dependent measured at no load Pumps operating in non-cavitating mode
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Standards Based on Machinery Type
Vibration Limits for horizontal clear liquid pumps, measured on bearing housing Hydraulics Institute
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Standards Based on Vibration Severity
Reciprocating Machinery type & size dependant load & mounting dependant < 3000 rpm frequency 2 - 300 Hz Steam Turbine Generator Sets Industrial Turbo Machinery (High Speed) Centrifugal Compressors Gear Units
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Standards Based on Machinery Type
Vibration severity limits for reciprocating machines
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Standards Based on Machinery Type
A good B Acceptable C Monitor closely D - Unacceptable
Vibration severity limits for large turbine generator machinery, absolute shaft displacement - ISO IS 7919 (part 2)
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Standards Based on Machinery Type
A good B Acceptable C Monitor closely D - Unacceptable
Vibration severity limits for industrial turbo-machinery, shaft displacement relative to bearings - ISO IS 7919 (part 3)
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Standards Based on Machinery Type
In-service vibration severity criteria for centrifugal compressors as a function of shaft speed Compressed Air and Gas Institute
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Standards Based on Machinery Type
Gear shaft vibration (displacement amplitude) vs. frequency ISO draft standard
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Unbalance Severity Chart
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ISO Standards
ISO Condition Monitoring Standards
ISO Reference 18431-1 18434-1 18436-1 Title Mechanical Vibration and Shock Signal Processing Part 1:General Introduction Condition Monitoring and Diagnostics of Machines Thermal Imaging Condition Monitoring and Diagnostics of Machines Requirements for Training and Certification of Personnel Part 1: Requirements for Certifying Bodies and the Certification Process Condition Monitoring and Diagnostics of Machines Part 2: Vibration Condition Monitoring and Diagnosis
18436-2
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ISO Standards
ISO Condition Monitoring Standards
ISO Reference 18436-3 Title Condition Monitoring and Diagnostics of Machines Accreditation of Organisation and Training Specialists - Part 3: Accreditation of Certification Bodies Condition Monitoring and Diagnostics of Machines Part 4: Lubrication Management and Analysis Condition Monitoring and Diagnostics of Machines Part 5: Thermography Condition Monitoring and Diagnostics of Machines Part 6: Diagnostics and Prognostics Condition Monitoring and Diagnostics of Machines Part 7: Condition Monitoring Specialists
18436-4 18436-5 18436-6 18436-7
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ISO Standards
ISO Condition Monitoring Standards
ISO Reference 14830-1 Title Condition Monitoring and Diagnostics of Machines Tribology Based Monitoring of Machines Part 1: General Guidelines Condition Monitoring and Diagnostics of Machines Tribology Based Monitoring of Machines Part 2: Lubricant Sampling Condition Monitoring and Diagnostics of Machines Vocabulary Condition Monitoring and Diagnostics of Machines Vibration Condition Monitoring: General Procedures Condition Monitoring and Diagnostics of Machines Data Processing, Communication and Presentation Part 1: General Guidelines
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14830-2
13372 13372-1 13374-1
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ISO Standards
ISO Condition Monitoring Standards
ISO Reference 13374-2 Title Condition Monitoring and Diagnostics of Machines Data Processing, Communication and Presentation Part 2: General Data Processing and Analysis Procedures Condition Monitoring and Diagnostics of Machines General Guidelines Condition Monitoring and Diagnostics of Machines Condition Based Maintenance Optimization Part 1: General Guidelines Condition Monitoring and Diagnostics of Machines Data Interpretation and Diagnostic Techniques General Guidlines
17359 22349
13379
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Training and Certification
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Training and Certification
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Training and Certification
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Training and Certification
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Training and Certification
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ISO Standards
ISO 6954 - 1984 Mechanical Vibration and Shock Guidelines for the overall evaluation of vibration in merchant ships ISO 8528/9-1995 Reciprocating Internal Combustion Engine driven alternating current generating sets Part 9: Measurement and evaluation of mechanical vibrations
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ISO Standards
ISO 1940/1-2002 Mechanical vibration Balance quality requirements of rigid rotors Part 1: Specification and verification of balance tolerances
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Acceptance Limits
Judging Overall Condition recognising changing machinery condition - time trends development and use of acceptance limits close to normal operating values to detect changes in condition tolerate normal operating variations without false alarms
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Acceptance Limits
Two types of limits: 1. Absolute conditions could result in catastrophic failure physical constraints, allowable movement before contact 2. Change limits provide early warning well in advance of absolute limit machine vibration limits based on standards and experience overall vibration levels
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Acceptance Limits
Note: the key to prevention is early discovery rates of change are also important expected time until limits are exceeded In General: high but stable vibration levels are of less concern than low but rapidly increasing levels. small % changes at high vibration levels are more significant than large % changes at low levels
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Acceptance Limits
Example: rolling element bearings distinctive defect characteristics typically slow progressive failure trend levels to achieve maximum useful life, failure avoidance However, rapid deterioration may occur due to: loss of lubrication lubrication contamination sudden overload
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Acceptance Limits
Note: changes in operating conditions can invalidate time trends speed or load changes may alter trends comparisons must take this into consideration
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Standards Based on Vibration Severity
Statistical Limits take as many vibration readings as possible average the overall level or some other parameter alert or warning levels set at 2.5 standard deviations provides optimum sensitivity to small changes maximum immunity to false alarms settings based on actual conditions - accommodates normal variations takes into account the initial condition of machine
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Standards Based on Vibration Severity
Judging Vibration Characteristics within the Frequency Spectra spectral components are directly linked to forcing functions more accurate for trending and diagnostics early detection of specific faults frequency domain analysis
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Standards Based on Vibration Severity
Limited Band Monitoring spectrum is divided into frequency bands total energy or highest amplitude trended within each band each band has its own limits based on experience 10 bands or fewer shows small changes in component specific frequency ranges band widths and limits must be machine & sensor type/location specific
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Standards Based on Vibration Severity
Rolling Element Bearing Spectrum
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Standards Based on Vibration Severity
Fluid Film Bearing Spectrum
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Standards Based on Vibration Severity
Gear Spectrum
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Standards Based on Vibration Severity
Narrow Band Monitoring same as limited band but with finer definition of bands Constant Band Width bands have same width at high and low frequencies constant speed machines
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Standards Based on Vibration Severity
Amplitude
Frequency
Constant Band Width
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Standards Based on Vibration Severity
Constant Percentage Band width band width remains a constant percentage of the frequency being monitored allows for small variations in speed
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Standards Based on Vibration Severity
Amplitude
Frequency
Constant Percentage Band Width
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Standards Based on Vibration Severity
Establishing a Reference Spectrum 1. Spectra from one good machine represents best condition for population. 2. Composite reference using vibration signals from all machines averaged together. 3. Each individual machine has its own reference (may be statistically derived if enough data is available). all samples must represent machine in good condition samples must be taken under normal operating conditions
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Standards Based on Vibration Severity
Minimum Threshold Values for Trends we are looking for trends and levels low levels will have a wide % variation set a minimum level below which variation is ignored this requires knowledge of machine & operating conditions best used together
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Next Time
Introduction to Machine Condition Monitoring and Condition Based Maintenance Basics of Mechanical Vibrations Vibration Transducers Vibration Signal Measurement and Display Machine Vibration Standards and Acceptance Limits (Condition Monitoring) Vibration Signal Frequency Analysis (FFT)
September 4, 2008 Page 66
