WELCOME

SEMINAR ON
PREDICTIVE MAINTANANCE USING VIBRATION ANALYSIS

PRESENTED BY: SAMIR KUMAR BOSE DEPT. MECHANICAL ENGG. ROLL NO: 0910300705 REGISTRATION NO: 091030110327

WHY PREDICTIVE MAINTENANCE?

-:PREDICTIVE MAINTENANCE TECHNIQUES: Vibration monitoring:

Thermography.

Tribology.(lubricating oil analysis, spectrographic analysis,

wear particle analysis.)

Ultrasonic.(leak detection, or material testing.)

-:VIBRATION ANALYSIS: Vibration monitoring is the most reliable method of assessing the overall health of a rotor system. Spectral analysis of vibrations has been used in rotating

machines fault diagnosis for decades.

When a mechanical part of the machine either wears or breaks up, a frequency component in the spectrum will change.

MOST COMMON MACHINERY PROBLEMS THAT

CAUSE VIBRATION INCLUDE: Misalignment of couplings, bearings and gears.

Unbalance of rotating components . Looseness . Gear wear . Rubbing . Electrical problems (unbalance magnetic forces) in motors. Resonance.

MACHINE VIBRATION: Repeating Forces:The term repeating forces refers to those unbalanced forces that occur over and over again within a machine to create movement. Repeating forces in machines are caused mostly by the rotation of imbalanced, misaligned,

worn or improperly driven machine components. Looseness:Machine parts that are loose may cause the machine to

vibrate. If parts become loose, vibration that normally is

acceptable may become excessive && damaging.

 Resonance:Most machines have at least one natural frequency of vibration, commonly referred to as natural oscillation rate. Although a repeating force may be small and result from the operation of a sound machine component, such a repeating force potentially may match the machines natural oscillation rate and create resonance. Frequency:A machine component typically vibrates at more than one frequency. This occurs because a variety of forces generally act upon a machine component during operation.

HOW VIBRATION IS ANALYZED

TIME DOMAIN - VIBRATION VS. TIME:-

A vibration signal is presented as a sinusoidal wave form with all frequencies and amplitudes combining to give one overall signal.

 F R E Q U E N C Y D O M A I N :-

By applying the FFT (Fast Fourier Transform) algorithm

to a Time Domain signal, it is converted to the Frequency Domain. In the Frequency Domain, each individual amplitude and frequency point are displayed here.

 COMPARATIVE ANALYSIS: Baseline Data:Baseline data sets should be acquired for each machine when the machine is installed.

Reset After Maintenance:The baseline data set must be updated each time the machine is
repaired, rebuilt, or major maintenance is performed.

Proper Identication:Each reference or baseline data set must be clearly and completely identied.

-:VIBRATION CONTROL METTHOD: Acceptance testing:It performed at the factory & immediately after installation can be used to ensure that new equipment

performs at optimum efficiency & expected life-cycle

cost.

 Noise control:Vibration analysis can be used to isolate the source of unwanted noise generated by plant equipment.

Leak Detections:A variation of vibration monitoring and analysis can

be used to detect leakage and isolate its source.

ISO STANDARDS FOR VIBRATION MEASUREMENTS:Recommendations are following: Measurement methods and parameters. Transducer selection, location, and attachment. Data collection. Machine operating conditions. Vibration monitoring systems. signal conditioning systems. Interfaces with data processing systems.

-:TYPES OF VIBRATION SURVEYS: Overall Vibration Steady State Synchronous

-:OVERALL VIBRATION: Outputs the sum of all vibration measured within a specified frequency range. Used as an initial alarm type survey, whereby if the overall indication is above a specified value,

a more detailed survey is performed to identify

the possible cause.

-:STEADY STATE:Used to measure vibration at a constant engine/component operational frequency. Used to determine the speed / frequency at which balancing should be performed.

-:SYNCHRONOUS:Utilizes a tachometer signal & a filter to track

vibration of a specific rotor or shaft.

Used to determine the amplitude of an imbalance condition.

-:EQUIPMENT:Sensor Selection:-

The first consideration is manufacturers recommendations. If none exist, then:

Frequency Range.

Environmental conditions.

Sensor:A transducer that converts mechanical motion into electronic signals. Three categories: Displacement.

Velocity.
acceleration.

 Displacement:- Measures the distance an object is

moving from a reference position. This distance is

typically reported in mils. Velocity:- Measures the rate of change of position an object is moving, and is commonly reported in Inches Per Second (IPS).Best suited to measure vibrations

between ~ 10 Hz and 1000 Hz, or 600 to 6000 RPM.

Accelerometer:- Measures the rate of change of

velocity per time period. Acceleration is reported in

Gs. Most effective frequency range for an accelerometer is above 1000 Hz, or 6000 RPM.

ADVANTAGES: Increased component operational life/availability. Allows for pre-emptive corrective actions.

Decrease in equipment or process downtime.

Decrease in costs for parts and labour. Better product quality. Improved worker and environmental safety. Energy savings.

DISADVANTAGES: Increased investment in diagnostic equipment.

Increased investment in staff training.

THANK YOU