Advanced Maintenance Technologies

Transcription

1 Advanced Maintenance Technologies Vibration Analysis Consultants Ray W. Wonderly Certified Vibration Specialist Services: Vibration Analysis Consulting Laser Alignment Services Predictive/Planned Maintenance Custom Training ISO Certified Vibration Institute Emerson Process

2 Advanced Maintenance Technologies Ray W. Wonderly ISO Certified Vibration Analyst Vibration Institute Emerson Process Predictive Technologies VIBRATION ANALYSIS

3 Vibration Analysis Overview Introduction

4 VIBRATION ANALYSIS AGENDA PURPOSE, SCOPE USING VIBRATION STANDARDS CASE HISTORIES BENEFITS OF VIBRATION ANALYSIS

5 VIBRATION ANALYSIS PURPOSE, SCOPE TO DETECT POTENTIAL FAULTS OF EQUIPMENT, THAT LEFT UNDETECTED OR UNATTENDED, COULD LEAD TO CATASTROPHIC FAILURE OF EQUIPMENT. TO VERIFY AND ASSURE EQUIPMENT IS OPERATING SATISFACTORY AND AS REQUIRED TO CERTIFY NEW AND REBUILT EQUIPMENT USING VIBRATION STANDARDS TO ASSURE QUALITY OF OPERATION

6 VIBRATION ANALYSIS PURPOSE, SCOPE EARLY DETECTION OF EQUIPMENT PROBLEMS TO ALLOW BETTER SCHEDULING OF MAINTENANCE WORK PERFORMED ON A AS NEEDED PROACTIVE BASIS VERSUS EMERGENCY OR CRISIS REPAIR PERFORM VIBRATION ANALYSIS AND TO ANALYZE, STORE AND TREND DATA FOR THE BENEFIT OF YOUR ORGANIZATION & RELIABILITY OF EQUIPMENT

7 Predictive Technologies Vibration Analysis (Root Cause) Infrared / Thermography Ultra Sound Laser Alignment Oil Analysis / Tribology Motor Current Analysis High Speed Video / Fiber Optics

8 What Is Vibration Analysis Of all the parameters to measure equipment, the vibration signature contains the most information The vibration signature not only provides information concerning the severity of a problem, but it also points to the possible source, or root cause of the problem

9 Vibration Analysis Substantial Reduction In Machinery Problems/Failures Extended Equipment Life Total Cost Savings Equipment Repairs, Maintenance & Plant Operations

10 Vibration Analysis Strengths Will give very early detection of potential fault (problem) Will give you the root cause of a problem (Unbalance, Misalignment, Bearings, etc.) Cost Savings Less major maintenance minor repairs vs. major catastrophic repairs

11 ALL MACHINES VIBRATE

12 EXCESSIVE VIBRATION IS A PROBLEM

13 ALL FAULT TYPES HAVE THEIR OWN CHARACTERISTIC VIBRATION PATTERNS

14 Frequency Domain (Spectra) Frequency & Amplitude Frequency Determines Type Of Fault Amplitude Determines Severity Of Fault

15 Important Machine Information Operating (Reference) Speed Of Machine Components such as Motor, Pump, Blower Equipment Must Be Running

16 Important Information Reference Speed Of All Components Bearing Information Belt Information Coupling Information # Vanes/Blades # Gear Teeth

17 Safety When Working Around Rotating Equipment Operational Speed 3600 RPM = 60 RPS 1800 RPM = 30 RPS Always Lock Out Equipment When Performing Maintenance Work

18 Types of Machinery Faults Unbalance Misalignment Mechanical Looseness Bearing Faults Vane & Blade Pass (Flow Disturbance) Gear Electrical (Air Gap, Stator, Rotor)

19 Vibration Analysis Program Database Structure Database Area Machine Train Machines (components) Measurement Points (measure types and alarms) Routes

20 Database & Equipment Structure

21 Vibration Analyzer/Data Collector

22 Acquire Data Established Routes

23 MIV MOV MIA MIH MOH

24 Download Data For Analysis/Reports

25 Information Things Management Needs to Know Machine/ID Problem found explanation Recommendations Priority or urgency according to severity

26 Initial Baseline Measures

27 Trending

28 Trending Fault Alarm Limit

29 Trend Data Hoffman #2 Fault Alarm Limit

30 Trending Before & After Repairs Fault Alarm Limit

31 Vibration Alarm Limit Threshold

32 Vibration (Amplitude) Measures Amplitude is the maximum value of vibration at a given location Displacement (Mils PK PK) Velocity (IPS PK or RMS) Acceleration (G s)

33 (Vibration) Amplitude Comparison Velocity & Displacement Machine 1800 RPM.250 In/Sec Velocity (Peak) 2.6 Mils (.0026) Displacement Peak-Peak

34 Spectra - Mass Unbalance Forcing Freq.= 1X Turning Speed 1170 CPM or Hz

35 Trend Data - Mass Unbalance

36 Spectra - Misalignment High 1x & 2x Turning Speed

37 Spectra Mechanical Looseness

38 Spectra Mechanical Looseness

39 Trend Data Mechanical Looseness

40 Spectra Bearing Defect

41 Spectra Bearing Defect

42 Spectra Bearing Defect

43 Spectra Bearing Defect

44 Trend Bearing Defect

45 City Of Eaton Water Treatment Facility Eaton, Ohio

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47 City Of Eaton Water Treatment Facility Vibration Analysis Program Implemented March 07, 2008 (Initial Baseline Measurements) Vibration Analysis Condition Monitoring on approximately 30 machines (pumps/blowers) Quarterly schedule (route structured)

48 City Of Eaton Water Treatment Facility Successful Corrective Action Repairs Hoffman Blower #3 Bent Shaft Filter Backwash Pump #1 Misalignment/Looseness Filter Backwash Pump #2 Mechanical Looseness Water Treatment Backwash #1 - Misalignment Mudwell #2 Mechanical Looseness Hoffman #2 Misalignment/Looseness East Lift Station Pumps 1 & 2 - Bearings

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53 Severe Misalignment & Worn Coupling in/sec peak 1x Operation Speed

54 AFTER REPAIRS.088 in/sec 1x Operation BEFORE REPAIRS in/sec 1x Operation

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58 MIV MOV MIA MIH MOH

59 .502 1x operation speed

60 After Alignment:.017 1x Operation Speed Before Alignment:.502 1x Operation Speed

61 City Of Fairfield Water Treatment Facility Fairfield, Ohio

62 Loose Bolts Booster Station Pump

63 EQUIPMENT: KAY DRIVE PUMP STATION #2 SURVEY DATE: JUNE 29, 2010 (Initial Baseline Measurements) FAULT TYPE: MECHANICAL LOOSENESS, COUPLING PROBLEM AND/OR BEARING DEFECT (PUMP) PRIORITY/URGENCY: HIGH PROBLEMS FOUND: Excessive vibration levels due to severe mechanical looseness of pump-inboard bearing (coupling side). Mechanical looseness of bearing area showing high frequency harmonics to operating speed. Time waveform shows very elevated acceleration levels in access of 20g s. RECOMMENDED ACTIONS: Assure mounting bolts of pump support and both bearings are secure. Inspect shaft coupling for damage and repair if needed. Check pump & motor shafts for looseness. Assure proper lubrication of pump coupling. Assure replacement parts/pump available for future repair.

64 KAY DRIVE PUMP STATION #2

65 Loose Bolts

66 Loose Bolts

67 Initial Baseline Measurements Severe Mechanical Looseness Pump #2

68 TREND DATA KAY DRIVE PUMP #2 After Repairs After Repairs

69 TREND DATA KAY DRIVE PUMP #2 Before Repairs After Repairs

70 TREND DATA KAY DRIVE PUMP #2 BEFORE & AFTER REPAIRS After Repairs After Repairs

71 TREND DATA Mechanical Looseness Bearing & Coupling After Corrective Action Repairs Pump #2 After Corrective Repairs

72 TREND DATA KAY DRIVE PUMP #2 After Repairs

73 City Of Fairfield Water Treatment Facility Fairfield, Ohio

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76 EQUIPMENT: BACKWASH PUMP #1 SURVEY DATE: SEPTEMBER 5, 2012 FAULT TYPE: UNBALANCE (MOTOR) PRIORITY/URGENCY: HIGH PROBLEMS FOUND: Excessive vibration levels due to unbalance of motor component. Vibration levels highest on outboard end of motor. RECOMMENDED ACTIONS: Check anti-backup clutch assembly (motor) for unbalance or damage. Check for proper amount of keystock of shaft key-way area of both motor and pump shaft and adjust length if needed. Balance motor if vibration levels increase. URGENCY: High

77 BACKWASH PUMP.496 in/sec Velocity Fault Alarm Limit Historical Trend Data

78 BACKWASH PUMP Fault Alarm Limit Historical Trend Data

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80 Balance Weights

81 BACKWASH PUMP After Balancing in/sec Before Balancing in/sec

82 BACKWASH PUMP After Balancing in/sec Before Balancing in/sec Fault Alarm Limit Historical Trend Data After Balancing

83 Montgomery County Western Regional Water Reclamation Facility

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85 EQUIPMENT: DRAIN PUMP #4 SURVEY DATE: JUNE (ORIGINAL WRITE-UP) FAULT TYPE: WORN COUPLING & MISALIGNMENT PRIORITY/URGENCY: HIGH PROBLEMS FOUND: Excessive vibration levels due to possible worn coupling and misalignment of motor and positrol speed drive shafts. Very substantial increase in vibration levels since last survey. RECOMMENDED ACTIONS: Inspect condition of shaft coupling and repair/replace if needed.

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88 Drain Pump #4

89 Before & After Repairs

90 Before & After Repairs

91 City Of Miamisburg Water Treatment Facility Miamisburg, Ohio

92 Acceptance/Certification Testing New or Rebuilt Equipment

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94 EQUIPMENT: LINDEN AVE. BOOSTER PUMP #2 SURVEY DATE: AUGUST 28, 2012 FAULT TYPE: MISALIGNMENT & POSSIBLE WORN COUPLING PRIORITY/URGENCY: HIGH PROBLEMS FOUND: Excessive vibration levels due to misalignment of motor and pump shafts. RECOMMENDED ACTIONS: Check condition of shaft coupling insert. Precision laser align motor and pump shafts. URGENCY: High. Schedule corrective action repairs at next opportunity.

95 Repaired Coupling Insert

96 Linden Ave Booster Pump #2

97 Linden Ave Booster Pump #2.816 in/sec Velocity Fault Alarm Limit

98 Linden Ave Booster Pump #2 Before & After Repairs.130 in/sec Velocity.816 in/sec Velocity

99 Linden Ave Booster Pump #2 Before & After Repairs

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107 Last Data.063 Operation Last Data

108 CONTACT INFORMATION: Ray Wonderly Advanced Maintenance Technologies Kiefer Rd. Germantown, OH