Mike Cannon © DLI Engr Corp - DLI Engineering Automated Bearing Wear Detection © DLI Engr Corp - Vibration: an indicator of machine condition Narrow band Vibration Analysis Vibration Contents by Frequency FFT Spectral Analysis Identify Peaks & Patterns - Relationship to machinery components Amplitude of peak – comparison to baseline Diagnosis and severity of machine problem Repair recommendations – © DLI Engr Corp - Specific to problem Priority and Remaining life Time Domain & Frequency Domain Vibration Wave Form A complex signal is the sum of several sine waves V ib r a tio n S p e c tr u m A m p litu d e v s tim e © DLI Engr Corp - F req u ency Vibration Data Acquisition & Processing Analog Signal is Digitized © DLI Engr Corp - Vibration Signal © DLI Engr Corp - Forcing Frequencies Rotation Rate of Fan Five-Blades on Fan Fly swatter against the blades Forcing Frequencies in Spectra IPS 1X RPM © DLI Engr Corp - Fly Swatter 10 10 O rders 18 Results = Problems Identified Detection Diagnosis & Motor Prognosis Gear Cprsr of specific problems © DLI Engr Corp - Imbalance Misalignment Bearings (BAD /COCKED) Bent shaft Looseness Out-of-round Journal Gear Problems Impeller Blade Problems Magnetic Noise Electrical Noise Accurate results from quality data All axes - more complete analysis Improves accuracy of diagnosis Permanently Mounted Stud Excellent frequency response Repeatability = accurate trending Barcoding Faster and more accurate Prevents human error WATCHMAN WATCHMAN TEST TEST POINT POINT 100 100 © DLI Engr Corp - Triaxial Sensor 100 100 DO DO NOT NOT PAINT PAINT Baseline Data to define the healthy machine © DLI Engr Corp - 10 800 Alarm Levels Diagnostic Report FIRE PUMP #2 Acquired: 8/19/03 10:35:38 AM 1xM = 1191 RPM Averages: RECOMMENDATIONS: MANDATORY: REPLACE MOTOR BEARINGS DIAGNOSES: EXTREME MOTOR BEARING WEAR © DLI Engr Corp - 51 0.056 (+0.042) in/s at 3.11xM on 2A in low range 0.028 (+0.025) in/s at 6.22xM on 2A in low range 0.039 (+0.030) in/s at 9.33xM on 2R in low range 0.079 (+0.077) in/s at 9.33xM on 2T in low range 0.001 (+0.000) in/s at 24.8xM on 2A in high range 0.088 (+0.084) in/s at 3.11xM on 2R in low range 0.022 (+0.021) in/s at 15.5xM on 2R in high range 0.022 (+0.011) in/s at 12.5xM on 2R in high range 0.039 (+0.036) in/s at 3.11xM on 2T in low range 0.001 (+0.001) in/s noise floor 0.002 (+0.001) in/s noise floor 0.001 (+0.001) in/s noise floor MOTOR BALL BEARING DEMOD Bearing tone harmonics in demod spectrum with direct match between regular and demod spectrum in 2R 21 dB peak at 9.33x on 2R © DLI Engr Corp - 52 Put it all together Bearing – The Movie © DLI Engr Corp - 53 The life and times of a troubled bearing Progression of Bearing Faults VdB Machine without Bearing Problems 120 1X 110 100 2X 90 3X 80 4X 70 60 © DLI Engr Corp - 54 ORDERS Progression of Bearing Faults VdB Slight Bearing Tones at 3.1X 120 1X 110 100 2X 90 3X 80 4X 70 60 © DLI Engr Corp - 55 ORDERS Progression of Bearing Faults VdB As defect worsens - 2nd harmonic rises 120 1X 110 100 2X 90 3X 80 4X 70 60 © DLI Engr Corp - 56 ORDERS Progression of Bearing Faults Increased machine looseness - 1X harmonics increase VdB 120 1X 110 2X 100 3X 4X 90 80 70 60 © DLI Engr Corp - 57 ORDERS 10 12 Progression of Bearing Faults VdB 1X Sidebands around the Bearing Tone 120 1X 110 2X 100 3X 4X 90 80 70 60 © DLI Engr Corp - 58 ORDERS 10 12 Progression of Bearing Faults VdB “Haystack” in Noise Floor appears as Wear Progresses 120 1X 110 2X 100 3X 4X 90 80 70 60 © DLI Engr Corp - 59 ORDERS 10 12 Bearing Tone Sidebands Bearing Tone VdB 140 130 Sidebands spaced at FTF 120 110 100 90 80 70 © DLI Engr Corp - 60 60 ORDERS Progression of Bearing Faults VdB Entire Noise Floor rises in advanced stages 120 1X 110 2X 100 3X 4X 90 80 70 60 © DLI Engr Corp - 61 ORDERS 10 12 Progression of Bearing Faults VdB Machine Failure 120 110 100 90 80 70 © DLI Engr Corp - 62 60 ORDERS 10 12 © DLI Engr Corp - 63 Summary of Analysis Techniques Data Normalization Automated Spectral Peak Extraction Cepstrum Analysis Noise Floor Calculation Rule-Based Diagnostics Demodulation Key elements in a successful MCA Information, not Data Measurement Methodology Triaxial Data Collection with mounting pad (Complete data set & improved high frequency signal: Portable/Walk-around approach) Superior Data Screening (Statistic baseline in hi/low freq range & automated, narrow band data comparison) Analysis / Diagnostics / Prognosis Automated Diagnostic Report with severity, fault and prioritized repair recommendation (information NOT just data) Information Everywhere Distribution of Information © DLI Engr Corp - 64 Simple, machine condition report/fault notification available via: Internet or automated pager, email, text message Delivering Machine Intelligence Delivering Machine Intelligence © DLI Engr Corp - 65 Visit our web site at: www.DLIengineering.com ... intermediate shaft bearings for looseness TURBO-GENERATOR (60HZ) #8 Important: Inspect accessory drive shaft for proper bearing fit and clearances Trend Reports Replaced Bearing © DLI Engr Corp -... CENTRIFUGAL PUMP © DLI Engr Corp - 23 CSDM (CSDM = Component Specific Data Matrix) Results from Automated Diagnostics © DLI Engr Corp - 24 Provides the most efficient machinery fault detection,... (PD) Bearing Tones Ball Pass Frequency – Inner Race BPFI Ball Pass Frequency – Outer Race BPFO Ball Spin Frequency BSF Bearing Train Frequency © DLI Engr Corp - 27 Ball Diameter (BD) FTF © DLI