Fluke Vibration Testing

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Introducing 810 Vibration Tester2010 Fluke Corporation

Get AnswersIntroducing Now. 810 Vibration Tester

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BeforeWeBegin Ask questions at any time! Please turn your cell phone to vibrate. If you must take a call, please feel free but we ask that you take it outside the seminar room.

2010 Fluke Corporation

Introducing 810 Vibration Tester

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Agenda Maintenance practices What is mechanical vibration? What are the benefits of vibration testing? How a vibration meter works Vibration basics Introduction to the Fluke 810 Vibration Tester Vibration Testing in 3 Easy Steps Setting up the machine Taking a proper measurement Interpreting the diagnosis Viewer PC software How to start testing vibration in your facility

2010 Fluke Corporation

Introducing 810 Vibration Tester

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MaintenancePractices ReactiveMaintenance:Oftencalledruntofailure. Norepairormaintenanceactions aretakenonmachineryuntilthedesignedlifespanisreachedorothervariables causethemachinerytofail. Upside: Lowerupfrontmaintenancecosts Lowermaintenancestaffcosts Unplanned,sometimescatastrophic,downtimeandovertimehours Secondarydamagetomachinesimpactedbythefailedmachine Potentiallyhighercapitalcostsasentirecomponentsmayneedtobereplaced Machinescontrolmaintenancedepartment

Downside:

PreventiveMaintenance(Proactive CalendarBased):AlsocalledHistoricalor calendarbasedmaintenance Upside: Increasedequipmentlife Reducedequipmentorprocessfailure Flexibilitywithmaintenancescheduling

Downside: Faultfreemachinesmaintainedunnecessarily couldleadtoincidentalproblemswith components Overhaulreducesreliabilityofthemachine(seethebathtubcurve) MorelaborintensivethanReactiveMaintenance

2010 Fluke Corporation

Introducing 810 Vibration Tester

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MaintenancePractices PredictiveMaintenance(Proactive ConditionBased):Useofdifferenttesting (vibration,thermography,oilanalysis,ultrasoundarethemostcommon)to understandmachineconditionandpreventfailure Upside Allowspreemptiveactiontoincreaseequipmentlife Increasedequipmentlife Reducedequipmentorprocessfailure Reducedrepairpartsandlaborcosts Increasedsafety Reducedlikelihoodofcatastrophicfailures Increasedinvestmentindiagnostic/testequipment Increasedinvestmentintrainingandstaff Costbenefitsnotreadilyseenbymanagement Mayrequiretopdownculturalchangeinmaintenanceapproach

Downside

Howismaintenanceperformedinyourfacility? Howoftendomechanicalbreakdownsoccur? Whatdoyoudotokeepmechanicalbreakdownsfromrecurring?2010 Fluke Corporation Introducing 810 Vibration Tester 5

EarlyIndicatorsofMachineHealth

Intheworldofmechanicalmaintenance,vibrationremains oneoftheearliestindicatorsofamachineshealth.Point where failure starts to occur P P = Potential Failure Wear Debris in Oil P-F Interval 1-6 mos P 1 P 2 Quantitative PM P-F Interval 5-8 wks P 4 P 5 P6

P 3

Heat By Touch P-F Interval 1-5 days

FThe P-F Curve, Adapted from John Moubrays book Reliability Centered Maintenance II

F = Failure

Withoverhalfofunplanneddowntimeattributedto mechanicalfailures,whyarentmorecompaniesinvesting invibrationanalysis?2010 Fluke Corporation Introducing 810 Vibration Tester 6

CurrentSolutionsNotforEveryone Currentvibrationanalysistoolsrequireacommitment Upfrontinvestment Fulltimeresourcestolearnandperformvibration analysis Manyfacilitiescannotmakethenecessaryinvestment, yetstruggledailywithmechanicalbreakdowns. Theonlyoptionsavailabletothesefacilitieshave included: Changingpartsregularlybeforetheywearout Outsourcingvibrationanalysistoconsultants Usingsubjectivetechniques Simplyfirefighting orrunningtofailure Maintenanceteamsneedhelpgettinganswerstotheir mechanicalproblemsNOW.

2010 Fluke Corporation

Introducing 810 Vibration Tester

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AVibrationProgramPaysforItselfCostofDowntime/Repair1.Netincomeperhourofoutputforproductionlineorothercriticalprocess 2.Calculatetheaveragedowntime(duetomechanicalfailures)foreachequipment failureandnumberofeventsperyear. 3.Multiplytheresultsofstep1bybothvaluesinstep2. 4.Estimatelabor(overtime)andequipmentpartscostperdowntimeincident 5.Addstep3andstep4.Thisistheannualcostinlostrevenueplusrepaircosts

Cost(RTF)$20,000/hr(critical&noncriticalmachinefailures) 8hrsdown,5motors,1x/yr ($20,000*8)*5=$800,000 $30/hr*8hrs*2techs=$480+$5000/motor=$5480 $805,480(duetocritical/noncriticalfailures)

CostofProgramImplementation1.Averagecostofcurrenttestequipment(hardwareandsoftware) 2.Averagecostofdedicated,experiencedvibrationtechnician(FTE)(Assume1man hour/motor/month) 3.Averageupfrontequipmenttrainingcosts+maintenancetraining 4.Addsteps1throughstep3.Thisisthetotalfirstyearcostofprogramstartup

Cost$30,000 1hr/mo/motor*150motors*12mos/yr*$35/manhr= $63000 $6000 $102,000

VibrationTestingPayback1.Assume50%ofunplanneddowntimeandrepaircostssavings 2.ReturnonInvestment&Paybackofvibrationtestingprogram(totalcostperyear/ totalsavingsperyear)

Cost$805,480*50%=$402,740 $102,000/$402,740=0.25yrsor3mos

Basicvibrationtestingprogramspayforthemselvesbutcurrentsolutionsaredesigned forexperiencedvibrationanalystswithinapredictivemaintenancecontext Upfrontcosts (hardware,software,training, headcount)canstillbehigh 2010 Fluke Corporation Introducing 810 Vibration Tester 8

BenefitsofVibrationTesting Vibration provides the earliest indicator of machine condition Vibration addresses all the moving parts of rotating equipment and can identify root cause Saves time by addressing problems earlier Saves money by reducing spare parts inventories

2010 Fluke Corporation

Introducing 810 Vibration Tester

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WhatisMechanicalVibration?

Vibrationistheoscillationofapoint,anobject,orapartof an objectaroundafixedreference,orrest,position. Sometypesofvibrationarebydesignmosttypesaresymptomsof otherproblemssuchasbearingcondition,shaftmisalignment, loosenessoroutofbalanceconditions. 2010 Fluke Corporation Introducing 810 Vibration Tester 10

MechanicsofVibrationTestingTransducerpicksup vibrationsignalsfrom bearinglocationsand transmitsthemtoa datacollectiondevice

Exampleofatimewaveform

Allrotatingequipmentgenerateauniquevibrationsignalorsignature Theseuniquesignalsareusuallycapturedinseries,withthesignals amplitude(yaxis)depictedovertime(xaxis).Thisiscalledatimewaveform.2010 Fluke Corporation Introducing 810 Vibration Tester 11

MakingVibrationDataEasiertoInterpretKindOf Thewaveformcontainsalltheinformationaboutthe vibrationofthemachineatthepointwhereitwas measured Buttheindividualpatternsofvibrationcausedbydifferent eventsinthemachinearealloverlappedandjumbled together.

Exampleofatimewaveform

FFT

Afrequencyanalysisperformedinthedatacollectoror softwareclarifiesandsimplifiesthetimewaveform data.Theresultiscalledavibrationspectrum(or vibrationsignature,FFT,orspectralplot.) Spectrumistheplotofthevibrationsignalsamplitude (yaxis)againstfrequency(xaxis)

Exampleofavibrationspectrum

Mostvibrationdatacollectors,analyzersandsoftwaregetyouthisfarbut atrainedtechnicianisstillrequiredtointerpretthedataintosomething meaningful andactionable2010 Fluke Corporation Introducing 810 Vibration Tester 12

CommonMachineFaults&SpectrumAnalysis Everymachineryfaultproducesaunique typeofvibrationsignal. Signalsdisplayedinthevibration spectrumoftenformcharacteristic patterns. Patternrecognitionisakeypartof vibrationanalysisbutsignificanttraining andexperiencearenecessarytoreadthe patterns. Inthisseminarwewillanalyze4different typeoffailures: Imbalance Misalignment Looseness BearingFailures

2010 Fluke Corporation

Introducing 810 Vibration Tester

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WhatisImbalance? Imbalanceisaconditionofarotatingpartwherethe centerofmassdoesnotlieontheaxisofrotation.In otherwords,thereisaheavyspot somewhereon therotor.Thelargepeakof124VdBat1Xrunningspeedis causedbytheimbalance.140 130 120 110 100 90 80 70 60 0 1 2 3 4 5 6 VdB

Theotherpeaksarecausedbydifferent phenomenainthemachine

ORDERS

2010 Fluke Corporation

Introducing 810 Vibration Tester

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SourcesofImbalance Variousmachineconditionscanresultinimbalance: Dirtaccumulationormissingbalanceweights Lackofhomogeneityinmaterials,especiallyincastings(e.g.poroussections, blowholes) Differenceindimensionofmatingparts(e.g.shaft,bore) Rollerdeflection(e.g.papermillrolls)ormachiningerrors Unevenmassdistributioninelectricalwindings Unevencorrosion,eccentricrotororerosionofrotors

Imbalance typically manifestsitselfat 1Xrunningspeed inanydirection

2010 Fluke Corporation

Introducing 810 Vibration Tester

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WhatisMisalignment? Inmachines,perfectalignmentoccurswhenthecenterlineoftwo coupledshafts coincide.Whentheydonotcoincide,misalignmentexists. Threetypesofmisalignmentarepossible: Angular thecenterlineofthetwoshaftsintersectbutarenotparallel.

AngularMisalignment

Parallel thecenterlineofthetwoshaftsareparallelbutnotconcentric.

ParallelMisalignment

ParallelandAngular(Common) mostmisalignmentisacombinationof angularandparallel

2010 Fluke Corporation

Introducing 810 Vibration Tester

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SourcesofMisalignment Misalignmentcanbecausedbyseveralsources,including: Poorassemblyorshiftingafterassembly Distortionduetopipestrain Distortionduetotorquecombinedwithflexiblesupport Temperatureinducedgrowthofthemachinestructure Poorlymachinedcoupling Inadequatecouplinglubrication

Misalignmentwillmanifestitself intwoways:

At2Xrunningspeed in theRadial&Tangential directions(parallel) At1Xrunningspeedin theAxialdirection (angular)

2010 Fluke Corporation

Introducing 810 Vibration Tester

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