Professional Documents
Culture Documents
Abstract:
Predictive maintenance (PdM) is an attempt to evaluate the condition of equipment by performing periodic or
continuous (online) equipment monitoring. The ultimate goal of PdM is to perform maintenance at a scheduled point
in time when the maintenance activity is most cost-effective, while maintaining the desired equipment performance
threshold. The condition monitoring of rotating bearings is a well know application of structure borne ultrasound,
however this is traditionally been limited primarily to fixed speed applications. With increasing focus on plant
automation and energy efficiency many traditional fixed speed motor driven applications are being fitted with
variable speed drives, resulting in variable machine loads. Traditional instantaneous condition monitoring
techniques, such as structure borne ultrasound, rely on a fixed baseline reference frame to determine any
abnormality for further investigation. Under variable load situations it is important to differentiate between a change
in the load condition and the presence of a condition abnormality.
This paper and corresponding presentation will demonstrate the successful implementation of a structure borne
ultrasound condition monitoring programme for variable speed applications in the New Zealand Dairy Industry.
Initially basic equipment was isolated and tested under laboratory conditions to determine the correct monitoring
methodology, followed by in-plant testing of live production equipment. The critical system parameters required to
successfully monitor variable speed bearings will be discussed, including the characterisation of the required speed
window, application load and recommended alarm levels. The primary benefits of this programme are the rapid
testing of more equipment than would otherwise be possible, thereby increasing the level of plant coverage for the
same maintenance budget spend.
.
1.0 Introduction:
Todays production focus is on increased speed,
accuracy, efficiency and economics. In the past
ultrasound and vibration technologies have been used
independently in the condition monitoring of bearings
in rotating equipment. It is becoming more
widespread to use ultrasonic inspection as a
complementary device to support vibration analyses
for bearing condition monitoring and failure
prediction methods.
2.0 Theory:
The typical Ultrasonic sampling frequency
recommended for bearing monitoring is 30Hz. The
relative loudness of the bearing can give a good
indication of the condition of the bearing if the
baseline value is known. The baseline, if not known,
can be taken as the lowest recorded noise that the
bearing gives off whilst under normal operating
conditions.
The speed ranges were not the same for each rig as
motor size, transmission ratios and application
dictated the operational envelope of each system.
Smart Pump
Pulp Screen
Water Flume Pump (vertical Impellor)
Air Heater Fan Motor
50
dB
24kHz
40
25kHz
30
26kHz
27kHz
20
28kHz
10
29kHz
30kHz
0
450
495
526
570
600
660
720
780
31kHz
32kHz
dB
50
24kHz
40
25kHz
30
26kHz
27kHz
20
28kHz
10
29kHz
30kHz
0
450
495
526
570
600
660
720
780
Figure 2: The Smart Pump test rig shown with Motor bearings (3
and 4) and Auxiliary bearings (1 and 2).
32kHz
50
Decibel Reading (dB)
31kHz
24kHz
40
25kHz
30
26kHz
27kHz
20
40
28kHz
30
10
Motor OB
20
30kHz
450 495
Pump IB
10
29kHz
Motor IB
526 570
600 660
720 780
31kHz
Pump OB
332kHz
0
400
500
600
700
800
RPM
dB
24kHz
40
25kHz
30
26kHz
27kHz
20
28kHz
10
29kHz
30kHz
0
450
495
526
570
600
660
720
780
31kHz
32kHz
Variance vs.Frequency
26
Varience (dB)
24
22
20
18
16
14
12
10
22
24
26
28
Frequency (kHz)
30
32
34
dB
60
24kHz
50
25kHz
40
26kHz
30
27kHz
28kHz
20
29kHz
10
30kHz
31kHz
594
1194
1487
1782
2390
2672
32kHz
33kHz
24kHz
50
dB
25kHz
40
26kHz
30
27kHz
20
28kHz
10
29kHz
30kHz
0
594
1194
1487
1782
2390
2672
31kHz
32kHz
1
4
3
60
24kHz
dB
50
Figure 4: The Smart Pump test rig shown with Motor bearings (3
and 4) and Auxiliary bearings (1 and 2).
25kHz
40
26kHz
30
27kHz
20
28kHz
10
29kHz
30kHz
0
594
1194
1487
1782
2390
2672
31kHZ
32kHz
50
40
30
Motor OB
20
Motor IB
60
10
Pump IB
50
Pump OB
40
26kHz
30
27kHz
20
28kHz
10
29kHz
dB
0
400
800
24kHz
25kHz
30kHz
594
1194
1487
1782
2390
2672
31kHz
Shaft Speed(Rpm)
32kHz
60
50
40
30
20
10
0
22
24
26
28
30
Frequency (kHz)
32
34
dB
24kHz
40
25kHz
30
26kHz
27kHz
20
28kHz
10
29kHz
30kHz
0
320 330 360 380 400 420 440 480
31kHz
32kHz
50
24kHz
40
25kHz
30
26kHz
27kHz
20
28kHz
10
29kHz
30kHZ
0
320 330 360 380 400 420 440 480
31kHZ
32kHz
dB
24kHz
40
25kHz
30
26kHz
27kHz
20
28kHz
Figure 6: The Water Flume test rig shown with Motor bearings (3
and 4) and Auxiliary bearings (1 and 2).
10
29kHz
30kHz
0
320 330 360 380 400 420 440 480
31kHz
32kHz
50
45
40
35
30
25
20
15
10
5
0
2.5
Motor IB
2.0
Varience (dB)
Pump SB
1.5
1.0
0.5
0.0
22
24
26
28
Frequency (kHz)
30
32
34
40
24kHz
35
25kHz
dB
30
26kHz
25
27kHz
20
28kHz
15
29kHz
10
30kHz
31kHz
0
1075 1116 1143 1170 1212 1252 1281 1307
32kHz
33kHz
24kHz
35
25kHz
dB
30
26kHz
25
27kHz
20
28kHz
15
29kHz
10
30kHz
31kHz
32kHz
Figure 8: The Fan Motor test rig shown with Motor bearings (3
and 4) and Auxiliary bearings (1 and 2).
50
40
30
Motor OB
20
Motor IB
10
0
1050
33kHz
14
12
10
8
6
4
2
0
22
24
26
28
30
32
34
Frequency (kHz)
1100
1150
1200
1250
1300
1350
RPM
The speed of the fans was not the same on each day
that readings were taken, as illustrated by the
variation in dB level seen for each bearing. The
critical alarm levels can still be readily identified, and
appropriate action planned and implemented.
7.0 Conclusions:
The condition of variable speed bearings can
effectively be monitored using structure borne
ultrasound. The primary prerequisite for any such
programme to be successful is the need to carefully
establish the baseline dB levels for each bearing
across the normal operational speed range for each
piece of equipment. Each variable speed bearing can
then be classified into one of three categories:
(a) Fixed speed bearing behaviour,
additional measures required.
Machinery
Bearing
Description
Fan 1
1
Fan 1
2
Fan 1
3
Fan 1
4
Fan 2
1
Fan 2
2
Fan 2
3
Fan 2
4
Fan 3
1
Fan 3
2
Fan 3
3
Fan 3
4
Fan 4
1
Fan 4
2
Fan 4
3
Fan 4
4
* Lubrication applied
(c) Significant variation in dB with speed (>1015 dB), establish a speed dependent baseline
and record speed as part of bearing PdM
route. Modern digital ultrasonic guns have
the capability to add this information as part
of the normal operation.
dB Readings
2/09
2/10
2/11
71
54
38
40
53
45
37
35
67
57*
36
41
72
50
31
37
68
53
40
39
48
40
35
37
62
48
38
37
75
50
31
40
66
52
42
38
47
38
50
40
63
49
38
35
77
51
33
38
D4 Exhaust
Fan No.
Fan 1
Fan 2
Fan 3
Fan 4
1
71
53
67
72
Bearing
2
3
54
45
57
50
38
37
36
31
no
4
40
35
41
37
By,
Dr James Neale
University of Waikato
Mr Gary Mohr
UE Systems Inc.
Introduction to Ultrasound
Where is Hamilton?
Economic Modelling
Capital Project Assessment
Energy Future Scenario Modelling
Presentation Overview
1.
Project Rationale
a.
b.
2.
Project Definition
a.
b.
3.
Laboratory Testing
a.
b.
Applications
Results
4.
In-Plant Implementation
5.
Conclusions
a.
KAURI
Fonterra
Overview
MORRINSVILLE
MAUNGATUROTO
WAITOA
TATUA
TE RAPA
CLANDEBOYE
STIRLING
EDENDALE
EDGECUMBE
LICHFIELD
REPOROA
1967
Drier 5 &
Co-generation
Plant
Commissioned
Drier 4
Commissioned
1990
Drier 1& 2
Upgraded
1991
1997
Cream Plant
Commissioned
1998
2006
New Packing
Lines
Commissioned
Key Products
Milk Powders:
Skim Milk Powder
Whole Milk Powder
Cream Products:
Butter
Anhydrous Milk Fat
Cream Cheese
High Fat Cream Cheese
Frozen Cream
Project Definition
1. Variable Speed Applications
a. Q: How does speed impact condition monitoring of
bearings?
b. Q: What is our acceptance standard?
2.
Test Variables
a.
b.
c.
d.
Speed
Test Frequency
Alarm levels?
How does the acoustic response vary with speed
for different applications/equipment?
Laboratory Testing
The following equipment was used to test
the effect of varying frequency and speed on
the ultrasound level recorded.
Smart Pump
Pulp Screen
Water Flume
Air Heater Fan
Smart Pump
Smart Pump
Bearing noise was measured in dB
at 4 points:
Motor
1 - Outboard Bearing
2 - Inboard Bearing
Pump
3 - Inboard Bearing
4 - Outboard Bearing
Motor Specifications:
25 kW
1475 rpm max.
4
Motor OB
30
Motor IB
20
Pump IB
10
Pump OB
0
400
500
600
RPM
700
800
Pulp Screen
Pulp Screen
4
Motor OB
30
Motor IB
20
Pump IB
10
Pump OB
0
400
800
Water Flume
Water Flume
1
Motor OB
20
Motor IB
10
Pump SB
0
300 325 350 375 400 425 450 475 500
RPM
Motor Specifications
4 kW
1445 rpm max.
1100
1150
1200
RPM
1250
1300
1350
Summary - Speed v dB
@ 30 kHz
Variation in speed had little effect on dB level of
motor bearings tested at this frequency (less than 5
dB).
Variation in speed had marginally greater effect on
dB level of the application (driven end) bearings (5
to 25 dB). Very application Specific.
Potential for actual in-plant usage bands to be quite
narrow, resulting in a lower dB band in practice.
24kHz
50
50
40
26kHz
30
dB
dB
40
20
26kHz
30
20
28kHz
10
28kHz
10
30kHz
0
450
495
526
570
600
660
720
780
30kHz
0
450
495
526
570
600
660
720
780
32kHz
32kHz
24kHz
50
50
40
26kHz
30
dB
dB
40
20
28kHz
10
26kHz
30
20
28kHz
10
30kHz
0
450 495 526
570 600
30kHz
0
450
332kHz
495
526
570
600
660
720
780
32kHz
60
50
40
24kHz
26kHz
28kHz
30
20
10
0
dB
dB
24kHz
30kHz
594
1194
1487
1782
2390
2672
32kHz
60
50
40
26kHz
30
20
10
0
28kHz
30kHz
594
1194
1487
1782
2390
2672
32kHz
33kHz
26kHz
dB
dB
24kHz
60
50
40
30
20
10
0
28kHz
30kHz
594
1194
1487
1782
2390
Shaft Speed(Rpm)
60
50
40
30
20
10
0
26kHz
28kHz
30kHz
594
2672
32kHz
1194
1487
1782
2390
2672
32kHz
24kHz
50
50
40
26kHz
dB
30
20
28kHz
10
26kHz
30
20
28kHz
10
30kHz
0
320 330 360 380 400 420 440 480
30kHZ
0
320 330 360 380 400 420 440 480
32kHz
dB
40
26kHz
30
20
28kHz
10
30kHz
0
320 330 360 380 400 420 440 480
Shaft Speed (Rpm)
32kHz
32kHz
24kHz
40
40
26kHz
26kHz
30
20
28kHz
10
0
20
28kHz
30kHz
10
30kHz
32kHz
dB
dB
30
33kHz
32kHz
1075 1116 1143 1170 1212 1252 1281 1307
Shaft Speed (Rpm)
33kHz
24
26
28
30
32
34
Pulp Screen
Frequency (kHz)
Smart Pump
Varience (dB)
Variance vs.Frequency
60
40
20
0
22
24
26
28
30
Frequency (kHz)
32
34
24
26
28
30
32
Fan Motor
34
Frequency (kHz)
Water Flume
Varience (dB)
Varience (dB)
15
10
5
0
22
24
26
28
Frequency (kHz)
30
32
34
In-Plant Implementation
Fonterra Te Rapa
Condition Monitoring Implemented across a range of critical
variable speed equipment
Water Pumps
Main Inlet & Exhaust Fans to Drier
MVR Fans: Drier Evaporator
Chilled Water Compressors (Ammonia)
Plate Freezer Compressors
VSD Air Compressor
In-Plant Implementation
Measurements
dB level
motor speed (using displayed speed or a hand held strobe)
Sound Files
Ultimate Objectives
Traffic Light Assessment
Green good
Red Bad
Amber recheck etc
Avoid Measuring Speed
Keep life simple
Sound File Primary Measure of Bad bearing
Capture Lubrication Fault in timely manner
Implementation
in Your Plant
Establish baselines
What are the speed limits?
High
Low
Thank you