Vibration training Course

Level 2/3

Bruno FOUILLE
ACOEM Asia Pacific
Predictive Maintenance
 Machine health - Repair and maintenance costs

Predictive m
aintenance t
ools

Pr
ev
Vibration
Infrared

en
Oil analysis

t iv
e
Unplanned repairs and 7$

m
ai
Can hear it
maintenance works are up to 7

nt
e
na
time more expensive than planned

nc
e
works

to
ol
5$

s
Can see it
1$ Failure
Time
Machine Health
Plenty of time for Little to no time for
Losses and maintenance
planning and organizing cost planning and organizing

1 - Preventive Maintenance 3
 Comparative maintenance cost

 Yearly maintenance cost (according to an ASME study)

 Reactive Maintenance costs: $22.8 per kW.
 Preventive Maintenance: $16.1 per kW.
 Predictive Maintenance: $10.7 per kW.

Predictive maintenance yearly cost is about

• 33% lower than preventive maintenance
22.5
• 17.5
47% lower than “Run to failure”
maintenance
12.5
7.5
2.5
Run to failure Preventive mainte- Predictive Mainte-
nance nance
Cost (USD) 22.8 16.1 10.7

1 - Preventive Maintenance 4
 Benefits

Reduction in lost Production

• Identify problems at an early stage in equipment so that necessary

downtime can be scheduled
• minimizes the probability of unexpected failures, and of lost production

Reduced Cost of Maintenance

• Equipment is only repaired when needed ( ≠ routine disassembly)

• Reduced maintenance cost: resources (labour, equipment and parts)
are only used when needed

Less Likelihood of Secondary Damage

• By identifying potential failures in advance, the severity of these

failures can be substantially diminished by reducing or preventing
secondary damage.

1 - Preventive Maintenance 5
 More Benefits

Reduced Inventory

• substantial warning of impeding failures is provided,

• parts can be ordered as required, rather than keeping a large backup
inventory.

Extending the Life of Plant Items

• machines are only dismantled when necessary,

• the frequency of equipment disassembly is minimized,
• and thus the probability of ‘infant mortality’ is reduced.

Improved Product Quality

• the efficiency of plant equipment is scrutinized constantly.

• By increasing the efficiency of your process, the quality of your product
will be improved.

1 - Preventive Maintenance 6
 Reliability chart

Condition-
Corrective Planned
ac

based
Maintenan Maintenan Upgrade
Maintenan
tatioAppro

ce ce
h

ce
Corrective Preventive

Monitoring
Analysis Expertise,
emen

Run to failure Systematic actions Diagnostic Diagnostic, and

n

Recommendation of upgrade Solutions

targeted actions
Impl

bility
in e
Mach
relia

1 - Preventive Maintenance 7
 Benchmarks

 Predictive maintenance could easily induces savings opportunities exceeding 30%

to 40%.
 In fact, independent surveys indicate the following industrial average savings
resultant from initiation of a functional predictive maintenance program:
 Return on investment: 10 times
 Reduction in maintenance costs: 25% to 30%
 Elimination of breakdowns: 70% to 75%
 Reduction in downtime: 35% to 45%
 Increase in production: 20% to 25%.
 U.S. Department of energy
 Federal Energy Management Program

1 - Preventive Maintenance 8
 Resources (vibrations)

# points measured & Staff required

analysed per month
0-50 points Readily done by maintenance engineer along with other
work
50-1500 points 1 technician doing field work,
sharing with 1 engineer
1500-3000 points 1 technician doing field work, 1 engineer to analyse, 1 to
evaluate,
depending on the degree of automated analysis
equipment used.
Over 3000 points More technicians for field measurements, again varying
with automation,
but keeping engineer staffing at 2.

1 - Preventive Maintenance 9
 Principles of predictive maintenance

 Predictive maintenance is based on the analysis of the trend of significant

parameters.

Critical level
Breakdown threshold Breakdown!

Projected
Maintenance threshold delay
before
breakdown

time

1 - Preventive Maintenance 10
 Advantages of conditional maintenance

 Impact of production shutdowns

 Unexpected failure  Scheduled shutdown

Production

Production
time time
Prod. Stop Prod. Stop Prod.

1. Decrease of unscheduled operations

2. Cost reduction
3. Improvement of availability
4. Improvement of security

1 - Preventive Maintenance 11
 Predictive maintenance

 Increased machine uptime

Benefits

 Maintenance costs reduction

 Increased machine durability
Advantages

 Failure prevention
 Cost effective targeted actions
 Better ability to plan maintenance actions
 Maintenance inventory cost reduction

1 - Preventive Maintenance 12
 Monitoring tools

 Vibration monitoring
 The most commonly used technique for the predictive maintenance of rotating
machines.
Advantages

 Easy measurements
 Early detection
 Collected data are rich

1 - Preventive Maintenance 13
 Monitoring tools

 Other techniques
 Lubricant analysis
 Thermography
 Monitoring of process parameters
- Temperature
- Pressure
- Flow
- Intensity, power
- etc.

1 - Preventive Maintenance 14
Defect examples
 Defect examples

Mechanical

• Mass unbalance
• Misalignment
• Looseness
• Gear
• Rolling element bearing
• Instability (journal bearing)
• Cavitation
• Greasing

Electrical

• Phase unbalance
• Stator shorts
• Broken bar
• Air gap

2 - Defect examples 16
 Mass unbalance

 Rotor wear

2 - Defect examples 17
 Electrical

 Rotor bar problem

2 - Defect examples 18
 Bearing

 Outer race defect

2 - Defect examples 19
 Bearing

 Rolling element defect

2 - Defect examples 20
 Bearing

 Inner race problem

2 - Defect examples 21
 Coupling

 Coupling wear

2 - Defect examples 22
 Gear

 Broken teeth

2 - Defect examples 23
Implementation basics
 Choosing the machines

3 - Implementation basics 25
 Implementation

Assets
selection Implementation
• 1 - Critical • Maintenance procedures
• 2 - Important • Kinematics
• 3 - BOP • Software / Hardware setting up

Solution Optimisation and

• Vibration
extension
• Online
• Offline
• Electrical
• Oil
• Thermography

3 - Implementation basics 26
 Route principle

 Measurement are set up in the database

 Based on the kinematics analysis of the machines
- Parameters
 Criticality
- Periodicity

 Periodical monitoring
 Before every route collection the configuration file will be loaded to the portable data
logger. This configuration file contains:
- Machines name and localization
- Measurement to be done
 After data collection the measure are uploaded to the database for analysis
- Trends monitoring is then possible

3 - Implementation basics 27
 Basic rules

 Same measurement location

 Report : noise, oil leak, dust, etc…

 Keep the periodicity

 Coordination with others:

 No measurement after greasing
 Measurement before and after any corrective action (alignment, balancing,….)

 Optimize the route

3 - Implementation basics 28
 Implementation of vibration monitoring

 Measurement periodicity
 The measurement periodicity is defined according to several parameters:
- the types of failure of the machine
- the criticality of the machine within the process
- the budget devoted to maintenance
 On Alarms, the periodicity is usually increased

Measurements

Time

3 - Implementation basics 29
 Non monitored machines

 Initial reading recommended

 Comparison in case of problems: baseline
 Faster reaction time
- The machines information are known : kinematics, etc…
- Settings already done

 Ideally after commissioning

 Otherwise, as soon as possible

3 - Implementation basics 30
 To remember

 The 4 main maintenance philosophies are :

 Corrective maintenance
 Preventive maintenance
- Conditional maintenance
- Predictive maintenance
 Predictive maintenance is based on the study of the trends
 The most popular tools for predictive maintenance are:
 Vibrations
 Oil analysis
 Thermography
 Process parameters monitoring

3 - Implementation basics 31
Vibration analysis basics
 Intuitive approach: vibrations

 Vibrations of a machine
 The vibrations of a machine are often felt by a simple hand contact on the structure.

 Vibrations that are felt originate

from forces internal to the machine.

4 - Vibration analysis basics 33

 Intuitive approach: noise

 Amplitude and frequency concepts

 The various noise sources can be analysed using:
- Amplitude: from the weakest to the loudest sound.
- Frequency: from the deepest to the highest sound.

 There is an analogy with an orchestra. Music is the sum of various amplitudes and
frequencies:
 the drum for deep (low-pitched) sounds
 the violin for high-pitched sounds.

4 - Vibration analysis basics 34

 Intuitive approach: vibrations

 Propagation of vibrations
 Vibration sources are mostly internal
 The vibration travels through the structure
 It is possible to evaluate the vibration source by measuring the vibration on the
structure

2 1
3
4

4 - Vibration analysis basics 35

 Intuitive approach: vibrations

 Influence of the structure

 For a given excitation (e.g., mechanical unbalance), the vibration response is different
depending on the point where it is collected:

Vibration = Excitation * Structure

 Measurements should be performed at the same point if they are to be compared

4 - Vibration analysis basics 36

 Fundamentals

 Principles of the vibration analysis of rotating machines

Machine
Noise
Internal Vibration Info. on stress
Structure Measurements
stress Effects and structure

 Unbalance
 Misalignment
The vibrations of a machine indirectly
 Bearings
reflect its internal strains.
 Meshing
 Magnetic defects
 etc.

4 - Vibration analysis basics 37

 Fundamentals

 Definition of a vibration according to Standard NFE 90-001

 A vibration is a variation in time of a amplitude characteristic of the motion or the
position of a mechanical system when this amplitude is alternately greater or smaller
than a given average or reference value. Vibration phenomena are more or less
complex periodic or aperiodic phenomena.

4 - Vibration analysis basics 38