DLI automated diagnost 05 2007

-Diagnostic System Development Large machine database, combined with years of repair history, and machine life cycle data is foundation for diagnostic system success... How does this spe

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-Diagnostic System Development

Large machine database, combined with years of repair history, and machine life cycle data is foundation for

diagnostic system success

planning of repairs

 All 3 axes - more complete analysis

 Improves accuracy of diagnosis

 Excellent frequency response

 Repeatability = accurate trending

 Faster and more accurate

 Prevents human error

-Level I Reports

Level I Reports

Level III Signatures

Level III Signatures

Level II Trends

Level II Trends

-Level 1 - Reports

 93% of erroneous analysis was in stating the severity level

 Diagnostic software best equipped to identify obvious faults andadditional faults (complete picture)

 67% of missed faults were where there was more than one fault,(missed multiple fault diagnosis)

-Tri-axial Display

Tri-axial Display

Tri-axial Display

Single axes Display

Single axes Display

Level 3 - Signatures

RATIO: 5.479 TO 1 RPM (INPUT/OUTPUT):

6410/1170 TYPE: SINGLE HELICAL, DOUBLE REDUCTION

CID : 016000340 TECH MANUAL : 347-2918 MFR: ALLIS CHALMERS OUTPUT: 595 GPM @ 65 PSIG RPM: 1160

TYPE: DOUBLE STAGE, SINGLE SUCTION, VOLUTE

TEST RPM’s AND OPERATING CONDITIONS

Machinery Knowledge Base

VIBRATION SOURCE COMPONENTS

DRIVER INTERMEDIATE OR AUXILIARY SHAFTS DRIVEN ITEM DESCRIPTION ELEM ORDER ITEM DESCRIPTION ELEM ORDER ITEM DESCRIPTION ELEM ORDER

t

Z1 T1 S1

G1

A B

Turbine Shaft (ref)

Nozzles

90 Degree Spacing Turbine Blading Reversing Chambers 12.6 Degree Spacing 10.5 Degree Spacing 8.3 Degree Spacing High Speed Drive Pinion

BEARING FUNCTION SKF 6211 R,T-t SKF 6211 R-t

3 40

27

1.00t

3.00t 4.00t 40.00t 28.60t 34.20t 43.40t 27.00t

I

G2 G3 G5

o

G6 OP

C D

Intermediate Shaft

High Speed Driven Gear Low Speed Drive Pinion Oil Pump Drive Pinion

Oil Pump Shaft

Oil Pump Driven Gear Oil Pump

BEARING FUNCTION

ND 41308 R,T-i

ND 41308 R, T-i

66 29 25

81 12

0.41t

27.00t 11.86t 10.23t

0.13t

10.23t 1.52t

p

G4 P1 P2

E F G H J

Pump Shaft

Low Speed Driven Gear 2nd Stage Impeller Vanes 1st Stage Impeller Vanes

BEARING FUNCTION TMK 7320 R,T-p TMK 7320 R,T-p MRC 7308 R,T-p MRC 7308 R,T-p Journal R-p

65 5 5

0.18t

11.86t 0.91t 0.91t

&

what are its vibration sources?

How does the Diagnostic System work?

What machine is this &

what are it’s vibration sources

What machine is this &

High Speed

Drive Pinion

BEARING SKF 6211

BEARING SKF 6211

Oil Pump

What machine is this &

what are its vibration sources?

What machine is this &

what are its vibration sources?

How does this spectra compare

to that of a healthy machine?

How does this spectra compare

How does the Diagnostic System work?

What machine is this &

what are its vibration sources?

What machine is this &

what are its vibration sources?

How does this spectra compare

to that of a healthy machine?

How does this spectra compare

to that of a healthy machine?

What, if anything, is wrong with

this machine and how bad is it?

What, if anything, is wrong with

How does the Diagnostic System work?

SCREENING OUTPUT TABLE

Pumps Centrifugal

7

Rotary Thread Pumps

8

Sliding Vane Pumps

9

Axial Piston Pumps

13

Generators

14

Centrifugal Purifiers

COMPONENT CODES

SCREENING OUTPUT TABLE

(CSDM = Component Specific Data Matrix)

CENTRIFUGAL PUMP

> 20% above Baseline on both sides of the coupling

3 The Maximum 2X > 06 IPS

(CSDM = Component Specific Data Matrix)

SCREENING OUTPUT TABLE

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?

Maintenance Planning

How does the Diagnostic System work?

Answers not just Data

We’ve automated the same steps a human analyst follows

It is not a black box!

 Avoid catastrophic failure or secondary damage

 Planned outage or maintenance period

 Stock long-lead-time parts for critical equipment

 Order parts in advance for planned shut downs

 Reset baseline & reference information

 Verify maintenance was performed correctly

 Health Assessment (e.g automated fault diagnostics using

rule-base expert system)

 Prognostic Assessment (e.g three levels of repair priority for takingmaintenance actions)

 Advisory Generation (e.g actionable information consists of

machine severity, specific fault (s), repair recommendation & priority

1 International Standard ISO Standard 133741-1 Condition monitoring & diagnostics of machines

 Alarm threshold generated

using statistical models

 Provides highly selective

machine condition (fault,

severity & repair priority)

proven over 25 years of

experience and use

 Reduces analysis, diagnosis

and report generation by an

order of magnitude compared

to manual analysis programs

 Based on five levels of fault

severity and three levels of

Automated Fault Diagnostics - Planning

 Schedule immediate repairs (Extreme

Faults) to avoid catastrophic failure or

secondary damage

 Schedule normal repairs (Serious

Faults) to plan outage or maintenance

 Reset baseline & reference information

 Verify maintenance was performed

correctly

 Problem Description with

specific fault severity

 Vibration detail showing

specific amplitude and

frequency triggered fault

Measure - Analyze - Document

 Measure / Collect Data

 Portable or Online

 Use other Technologies

(Oil, IR, Motor, Ultrasound)

 Analyze / Screen Data

 Time, Spectra, Demodulation,

Run Down, Trends, Waterfall

 Document / Report / Distribute

 Fault, Severity, ACTION

Machine Condition Assessment (MCA)

Analyze / Diagnose – Motor Imbalance

Boiler Circulating Water Pump/Motor 1B

Report generated on: 5/30/01 05:44 PM

ACTION with Priority

Desirable Important Mandatory

Specific Fault(s) Note: Over 950 fault templates available for 47 machine

AND 1 x Vertical > average baseline @ Motor

> 1 x Horiz Delta + 1 x Vert Delta @ Pump

1 x Vert > 1 x Axial @ Motor

& Vertical Directions (parallel)

• At the Rotational Rate in the Axial

direction (angular)

 High 2x amplitude in radial

directions and 1x in axial direction

 Significant exceedance above

SLIGHT PUMP INTERNAL LOOSENESS

SLIGHT MOTOR BALL BEARING SIGNIFICANT DEMOD

Germany

text messaging or email

 Access to machine data &

condition information via your

Web Browser

 View information on any

machine in database

 List of Machines by Severity

 Automated Diagnostic Results

 Spectral Plots

 Severity Trends

 Speed normalization

 Average spectra as a baseline

 Cepstrum analysis for bearing tone detection

 Component specific data and rules application

 Original database of over 10,000 machine tests

 Rulebase development and refinement continues

 Currently our machinery test database grows at a rate of over 2000 machine tests a month,

 Every one of the tests reviewed for expert system versus human analysis agreement as part

of an ongoing quality improvement program.

 This regular methodical review of the results provides expert system report corrections

which are forwarded to the plant managers

 A good machine being reported by automated system as faulty

r

 Axial, Vertical and Horizontal (A, V, H)

 At least one test location and sometimes two per major machinecomponent isolated-by a flexible coupling

flo

Methodology Basis 3: Order Normalized Vibration Data

 The expert system automatically finds the running speed of each machine.

 Order normalizing allows

 Analyst or expert system quickly identify peaks

 The expert system readily identifies probable bearing tones and detects rotational rate sidebands.

 Most important, it allows

 The creation of an average data file

 Combining Vibration signatures for

 identical machines

 different times

 slightly different operating speeds

© DLI Engr Corp - 50

 Composed of normalized vibration signatures of:

 relatively healthy machines

 physically identical machines

© DLI Engr Corp - 52

 Amplitudes at each of ten pre-selected, specified orders, (screening criteria or fault codes)

 Amplitude and rotational rate order of :

 the two highest peaks in each of the low range and high range spectra, excluding the ten specified peaks.

 “Floor” level below which are the amplitudes of 75% of the remaining spectral lines of the high range spectrum.

 For each of the above,

 Thus we have 14 distinct peaks plus the “floor” noise level tabulated for each axis

 A cepstrum can be defined simply as the spectrum of a spectrum.

 Characteristic peaks in the cepstral data occur at positions corresponding to frequencies at which there exists a strong series of peaks or spacings in the spectrum.

 A machine with a faulty antifriction bearing may show a harmonic series of

peaks with 3.12 times rotational rate spacings in the spectral data (i.e peaks at 3.12,6.24,9.36 etc.).

 This series of peaks would then show up in the cepstral data as a single peak at

a position corresponding to the frequency of 3.12 times rotational rate.

Motors Gearboxes Linked Drives (belt or chain) Centrifugal Pumps

Rotary Thread/Gear Pumps Rotary Sliding Vane Pumps Reciprocating Pumps Fans

Centrifugal Compressors Reciprocating Compressors Screw Compressors Lobed Blowers Generators Purifiers Couplings Diesel Engines Marine Propulsion Gearboxes Machine Tool Spindles

SCREENING OUTPUT TABLE

(CSDM = Component Specific Data Matrix)

r