DLI auto bearing fault 05 2007

LUBE OIL SERVICE PUMP ATTACHED #1C Important: Inspect bevel gears for proper meshing; if satisfactory, check intermediate shaft bearings for looseness.. TURBO-GENERATOR 60HZ #8 Important

Mike Cannon DLI Engineering

Priority and Remaining life

Narrow band Vibration Analysis

-Time Domain & Frequency Domain

Vibration Wave Form

 All 3 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

100 90 80 70 60 110-

Frequency in Orders (multiples of rotation rate)

Level I Reports

Level II Trends

Level II Trends

Level III Signatures

Level III Signatures

1 MANDATORY Repair Recommendations

AIR CONDITIONING SALTWATER CIRCULATING PUMP #3

Mandatory: Overhaul unit.

AUXILIARY MACHINERY COOLING WATER PUMP #2B

Mandatory: Align Motor and Pump.

2 IMPORTANT Repair Recommendations

MAIN CONDENSATE PUMP (MD) #1A

Important: Replace motor bearings.

Desirable: Monitor pump bearings for increased vibration.

LUBE OIL SERVICE PUMP (ATTACHED) #1C

Important: Inspect bevel gears for proper meshing; if satisfactory, check intermediate shaft bearings for looseness.

TURBO-GENERATOR (60HZ) #8

Important: Inspect accessory drive shaft for proper bearing fit and clearances.

MCA Results - Summary Report

of Data Collection

 Triaxial, order-normalized data

 Machine specific, statistical baselines

 Feature extraction &

Internal Functions Output

 Specific faults & severity

 Repair recommendations

 Email & pager ALERTs

 Network replication

 OPC & XML connectivity

 Web Connect browser access

Automated Diagnostic Systems

Machinery Fault Report

What machine is this &

what are its vibration sources?

How does this spectra compare

to that of a healthy machine?

What, if anything, is wrong with

this machine and how bad is it?

Complete sets of high resolution vibe data for FFT, cepstrum & demod

Machine configuration data, (VTAGs) coupled with

component specific fault templates

Detection diagnosis & prognosis

Actionable Information

Feature extraction and exceedance table

Pumps Centrifugal

7

Rotary Thread Pumps

8

Sliding Vane Pumps

9

Axial Piston Pumps

13

Generators

14

Centrifugal Purifiers

Features from comparison to baseline

SCREENING OUTPUT TABLE

(CSDM = Component Specific Data Matrix)

Fault Models / Diagnostic Flow

Results from Automated Diagnostics

 Provides the most efficient machinery fault detection,diagnosis & prognosis to insure:

 Immediate local fault detection & actionable information

 Optimal asset reliability and machine life extension through prognosis of how & when machine should be repaired

Rolling Element Bearing Detection

Fault Indicators in Vibration Spectra

Bearing Tones

Non-integer peaks and harmonics relative to component rotation rate Sidebands

Noise floor elevation High frequency indicators

Impact and Ringing Modulation

Inner ring face Outer ring face

BPFO Ball Spin Frequency

BSF Bearing Train Frequency

FTF

d d

d d

d d

d d

 Usually 1X Around BPFI

 May be FTF Around Bearing Tones

Rolling Element Bearings

For each shaft revolution:

4.6 balls will pass an outer race defect The ball will make 2.02 revolutions

7.4 balls will pass an inner race defect

The cage will make 0.38 revolutions

Calculated Bearing Tones

 Bearing tones do not always appear at the expected,calculated frequencies

 User does not always have correct bearing information

 Diagnostic System designed to work independently ofcalculated bearing frequencies

 User may overlay calculated frequencies on graph ifdesired

VdB

Bearing Tone 4.6X

Synchronous Components

are integer multiples of

shaft rotation rate

Bearing tones are

non-integer multiples

of shaft rate

Automated Spectral Peak Extraction

 Identify Shaft Rate Peak(s)

 Identify Harmonics of Shaft Rate(s)

 Identify Forcing Frequencies

 Identify External Vibration

 Extract non-defined, non-synchronous peaks aspossible bearing tone candidates

70 80 90 100 110 120 130 140 CdB

1X Harmonics Bearing Tones

 Extracts Periodicities From the Spectrum

 Separates Different Harmonic Series

 Separates Sideband Families

 Is Useful in Automating Bearing Wear Detection

 Bearing Model Is Not Required!!!

 Is this bearing tone candidate part of a family of peaks?

Bearing Impact Faults

High-Frequency Damped Oscillation

Acceleration Wave Form Spall

Demodulaterd Waveform

 Early Warning of Bearing Wear

 Confirmation of Bearing Wear

 Better Information on Which Bearing is Defective

EXTREME MOTOR BEARING WEAR

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

Bearing – The Movie

The life and times of a troubled bearing

120 VdB  Increased machine looseness - 1X harmonics increase

1X

2X

3X

4X

120 VdB  1X Sidebands around the Bearing Tone

1X

2X

3X

4X

120 VdB  “Haystack” in Noise Floor appears as Wear Progresses

1X

2X

3X

4X

100 110 120 VdB

120

VdB  Machine Failure

Key elements in a successful MCA

Information, not Data

 Analysis / Diagnostics / Prognosis

 Automated Diagnostic Report with severity, fault and prioritized repair recommendation (information NOT just data)

Information Everywhere

 Distribution of Information

 Simple, machine condition report/fault notification available via:

 Internet or automated pager, email, text message

Delivering Machine Intelligence

Delivering Machine Intelligence

Visit our web site at:

www.DLIengineering.com