1

Advanced Condition Monitoring Techniques Applied in Mining.

By Peter Watson, Vibration Engineer, U.K. Coal Mining Ltd.


Abstract

Historically third party specialists have always provided condition monitoring services to U.K.Coal.
In 1999 the management at U.K.Coal decided to bring the condition monitoring function In
House.
Many different Software and Hardware packages were researched.
Emerson Process Management were invited into a working partnership with U.K. Coal.
We were particularly impressed by the powerful analysis features available in their Machinery
Health Manager Software, allowing the oil and vibration programmes to run from a single platform.
Emersons were also able to offer hardware solutions by the means a C.S.I. data collector that would
meet the legislative requirements required to take the instrument underground into a hazardous
environment.
A Used Oil Analysis Laboratory was set up at the company Head Quarters in Doncaster along with
individual R.C.M. departments at each mine. Each mine collecting and managing the used oil
samples before forwarding them to the lab, as well as running a vibration monitoring programme.

In this paper I aim to show some of the success achieved by the R.C.M. programme operated by
U.K.Coal.

Diagnosing Machinery Faults using Vibration Analysis
Vibration analysis is a non-invasive test, which tells us a machines condition whilst the machinery is
under load. We use this data to help diagnose machinery faults.
Each machine defect generates a specific vibration characteristic, which is determined by the
machines geometry and operating speed. A single vibration measurement can provide information
about multiple components, including:
Imbalance
Misalignment
General Looseness or Wear
Bearing Defects
Gear Defects


In the first section of this paper I aim to provide case studies of how the Vibration Monitoring
Programme has successfully highlighted various types of defects, allowing corrective actions to be
taken in planned maintenance periods.










2
Imbalance Fault
The first case study covers an Imbalance fault detected at Wistow Mine on their Main South Intake
conveyor. At the time the fault was detected the conveyor was providing coal clearance for two
single entry faces and four developments.
Figure 1 shows a waterfall plot of vibration data collected from the input shaft of the gearbox in a
radial plane. The waterfall plot is an analytical feature within the software that allows the annalist to
analyse the data, also allowing the data to be trended.
The highlighted synchronous peak at 24.9Hz (one order of rotation) indicates vibration at the
frequency of the input shaft, at an amplitude of 11.54mm/s. A considerable increase can be seen in
the shaft frequency vibration compared to the data collected on the 26
th
of April.

Figure 1.
















A work instruction was raised, requesting that the input shaft assembly be inspected, paying
particular interest to the coupling security.
On inspection three of the six motor to resilient plate bolts were found to have come adrift, and the
resilient plate was found to be broken and cracked. See figure 2.

Figure 2.



















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Frequency in Hz
SIT - DRIVE 1
DRIVE1 -G1H Shaft 01 Inboard Vertical
0 20 40 60 80 100 120 140
0
3
6
9
12
Max Amp
11.5
10:58:41
26-Apr-01
12:22:54
11-May-01
11:45:52
14-May-01
RPM= 1470.
12:22:54
11-May-01
Freq:
Ordr:
Sp 2:
Dfrq:
24.90
1.016
11.54
.00000



C
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a
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11: May 01
12:22
RPM1470
Freq. 24.90
Ordr: 1.016
Spec: 11.64
3
The work order was raised on a Friday, the inspection and repairs were carried out over the
weekend which was a planned non production period, with the conveyor being available to run
on the Monday morning, with no delay to production. Figure one shows the vibration at shaft
frequency returned to a acceptable level after the corrective works had been carried out.

Misalignment
Shaft misalignment is another problem that can be detected using Vibration Analysis, which if
left un-corrected can lead to seal failure, which then leads to dirt and water ingress, which then
leads to oil contamination leading to bearing failure, thats if the bearing hasnt already failed
due to the stresses induced by the misalignment.
Vibration analysis can detect parallel offset misalignment, angular misalignment, more often
than not both are experienced.













My next case study covers a misalignment fault detected on the North East Booster Fan at
Maltby Colliery.
The online vibration monitoring system detected an high level of low frequency vibration when
the fan was re started after an annual maintenance inspection.
Because of this detailed vibration data was collected aiming to determine the nature and severity
of the excessive low frequency vibration.
Figure 3 shows a single vibration spectra collected in a radial plane from the fan bearing. The
highlighted synchronous peak at Two Times Shaft Frequency indicating offset misalignment.




















Angular
Both
Offset
4
Figure 3.



Laser alignment equipment was used to check the shaft alignment condition, with measurements
being taken from the fan assembly and inputted into the alignment computer. The alignment
computer then makes a calculation as to the alignment condition once alignment measurements
have been taken. See figure 4

Figure 4.

The alignment condition was found to outside of an acceptable tolerance. The laser was used to
re-align the shafts to with in an acceptable tolerance band. See figure 5.

Figure 5


















NEBF - NE BOOSTER FAN
NE BOOSTER-F1H FAN DE
Route Spectrum
19-Jul-04 10:47:42
OVERALL= 6.11 V-DG
RMS = 6.07
LOAD = 100.0
RPM = 1493. (24.88 Hz)
0 50 100 150 200 250 300 350
0
1
2
3
4
5
6
7
8
Frequency in Hz
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Freq:
Ordr:
Spec:
49.92
2.006
6.016
Freq. 49.92
Ordr: 2.006
Spec: 6.019
5





Further vibration data was collected to access the level of improvement after the corrective
actions had been completed. Figure 6 shows a waterfall plot of vibration data taken from the
fan bearing. The data collected 15
th
of June 01 shows acceptable levels of vibration at two
times shaft frequency, with an increase at this frequency being recorded after the maintenance
works had been carried out. A return to acceptable levels of vibration was recorded after the
shafts were realigned, data 21
st
July 04.


















6
Figure 6.

The software allows various parameters to be trended, with a trend of the 2 times shaft frequency
parameter, indicating a return to acceptable levels of vibration. See figure 7.

Figure 7.








NEBF - NE BOOSTER FAN
NE BOOSTER-F1H FAN DE
Trend Display
of
2xTS
-- Baseline --
Value: .397
Date: 19-Sep-01
0 20 40 60 80 100
1
2
3
4
5
6
7
Days: 04-May-04 To 05-Aug-04
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Date:
Time:
Ampl:
19-Jul-04
10:47:48
6.028
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Frequency in Hz
NEBF - NE BOOSTER FAN
NE BOOSTER-F1H FAN DE
0 20 40 60 80 100 120 140
0
1
2
3
4
5
6
Max Amp
5.23
10:35:01
15-Jun-04
10:47:42
19-Jul-04
08:18:52
21-Jul-04
RPM= 1493.
10:47:42
19-Jul-04
Freq:
Ordr:
Sp 2:
Dfrq:
50.31
2.022
5.997
.00000
7
SKF state that 34% of bearings fail prematurely due to abuse in service. It is important that any
misalignment is corrected as soon as possible, preventing any secondary damage from occurring.


Rolling Element Bearings.
Probably the most detected fault using vibration analysis techniques are faults with-in Rolling
Element Bearings. We are able to accurately predict four defects with in a bearing. See figure 8.

The Four Bearing Defect Frequencies




Ball Spin
Frequency
Bearing Cage
Frequency
Ball Pass
Frequency
Inner Race
Ball Pass Frequency
Outer Race
(BPFO)
8
My third case study covers a bearing fault detected at Gascoigne Wood Mine on their Anderson
Strathclyde Conveyor using vibration and oil analysis techniques.

Gascoigne Wood Mine was the coal handling plant for the Selby Coal Field. The mine was designed
to process the output of five deep mines via two conveyor systems. At the time of the bearing fault
only three mines were in production, Wistow, Stillingfleet and Riccall producing five million tonnes
per annum. The Selby Coalfield ceased production in November 2004.
The A.S.L. Conveyor is 12.2 Km long, with a capacity of 3500 tonnes per hour and with a lift of
800m, achieving over 98% availability.

Figure 9 shows a plan of the Selby Coal Field.










































9
A bearing defect was detected at our oil laboratory whilst carrying out routine oil analysis on a drive
deflection drum. (see fig.10)

Figure 10 shows the oil sample report from the Conveyor Drum in question, with large ferrous particles
being present in the oil between three hundred and eight hundred microns.

Figure 10.


































At this time routine vibration data was not being collected due to access restrictions. As a
result of the concerns highlighted by the oil analysis programme, remote accelerometers were
fitted and vibration data was collected to determine the severity and nature of any defect. See
figure 11.








MR I.DIXON,
GASCOIGNE WOOD MINE.
Readings appear stable; some large ferrous particles were found, indicating much
heavier than normal wear. Also there are a few very large non-magnetic particles,
could be from a bronze cage. Check vibration for bearing activity.
We would advise change and/or inspection at the next opportunity.
10
Figure 11 shows a single Vibration Spectra and Time Domain Waveform taken using C.S.I.
Peakvue technology from the right hand bearing of the snub drum.
The Spectra indicating a bearing defect.
Figure 11.





















No bearing specifications were available as the bearings were non-standard, specifically
designed for the application. Although bearing specifications were not available it was
apparent the bearing was in the final stages of failure.
The severity of any defect using Peakvue Technology is judged by analysing the Peak-to-Peak
amplitude in the time domain waveform. With force being proportional to speed a
conservative alarm for a bearing operating at this frequency would be 1g Peak to Peak.
Rule of thumb calculations were used, aiming to identify the defective component with in the
bearing.

Ball Pass Freq. Inner Race = No Rolling Elements*Rotational Freq.*0.6
12.5 = ? * 1.77 *0.6
After transposing the formula I calculated the predicted number of rolling elements to be
11.77. If that number is rounded up to 12 the Fundamental Fault Frequency rises by only
0.2Hz to 12.7Hz

Ball Pass Freq. Inner Race = No Rolling Elements*Rotational Freq.*0.6
= 12 * 1.77 *0.6
Ball Pass Freq. Inner Race = 12.7Hz


A spare drum was available, this was inspected and a component change was planned. The
change out of the drum ran for three twelve-hour shifts over a planned non-production period.
On investigation the inner raceway of the bearing was defective as predicted.





ROUTE WAVEFORM
31-Oct-03 08:30:33
(PkVue- HP 500 Hz)
PK = .9137
PK(+) = 5.13
PK(-) = .2505
CRESTF= 7.95
0 3 6 9 12 15
-1
0
1
2
3
4
5
6
Revolution Number
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ASL - SNUB DRUM
ROLLER 5 -R2P SNUB DRUM NORTH BEARING
ROUTE SPECTRUM
31-Oct-03 08:30:33
(PkVue- HP 500 Hz)
OVERALL= .4592 A-DG
PK = .4568
LOAD = 100.0
RPM = 106.
RPS = 1.77
0 50 100 150 200 250 300 350 400
0
0.04
0.08
0.12
0.16
0.20
0.24
Frequency in Hz
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Freq:
Ordr:
Spec:
12.50
7.069
.167
Fault frequency @12.5Hz
11
Figure 12. shows the inner raceway of the bearing



























Figure 13 shows the drum shaft and bearing parts.


12

Figure 14 shows the bearing cage and rolling elements.



Figure 15 shows an Overall Value Trend of the vibration measurements taken, up to a point
where the drum was changed.

Figure 15.


















ASL - SNUB DRUM
ROLLER 5 -R1P SNUB DRUM SOUTH BEARING
Trend Display
of
Overall Value
-- Baseline --
Value: .216
Date: 28-Oct-03
0 2 4 6 8 10 12 14
0.12
0.18
0.24
0.30
0.36
0.42
Days: 31-Oct-03 To 13-Nov-03
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Last reading before drum was changed
13

Conclusion
Had the fault not been detected and the bearing in question subsequently failed in service
Riccall Mine would have lost two days production, Wistow and Stillingfleet Mines would
deliver onto the standby conveyor running at reduced capacity.
Due to the design of the drum amounts oil debris collected were inconsistent. The fault would
have been confirmed earlier had vibration data been collected, reducing the risk of an
unplanned conveyor stoppage.
With SKF quoting that 16% of bearings fail prematurely due to poor fitting, 36% due to
inadequate lubrication and 14% failing prematurely due to contamination. I feel that it is
important that bearings are monitored to predict these problems, so corrective actions can be
taken, reducing the risk of bearing failure.



Poor Gearbox Build Highlighted using Vibration Monitoring Techniques.

The gearbox in question had been over hauled at our workshop facility. The gearbox was then
sent to one of our suppliers for testing on their test rig.
The unit in question was a Meco 400 Horse Power 28:1 gearbox to be fitted to an in line chain
conveyor, carrying coal for one coal face and four tunnel drivages at Stillingfleet Mine.

Figure 8 shows a single vibration spectrum taken from the input shaft of the gearbox.
The first highlighted peak of 499Hz indicates the gear mesh activity between the first and second
gear. Gear mesh activity is a natural characteristic of gears in mesh, but the excessive side band
activity evident indicates excessive clearance between the gear flanks. By measuring the
sideband peaks we can determine which of the two meshing gears are a cause for concern.

Figure 8.

STIL - S400T 28:1 GEARBOX
S/FLEET -G1H Shaft 01 Inboard Horizontal
Route Spectrum
15-Jul-03 09:46:18
OVERALL= .3927 A-DG
PK = .3919
LOAD = 100.0
RPM = 1498.
RPS = 24.96
0 500 1000 1500 2000
0
0.03
0.06
0.09
0.12
Frequency in Hz
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Freq:
Ordr:
Spec:
499.18
20.00
.08772
>JOY S400T
F=Grmesh(1>2)
F F F F
Sideband activity
Gear Mesh Frequency @ 499Hz
14

Meco ST400 28:1 Gearbox

Figure 9 shows a plan of the gearbox, with gear mesh calculations.

















Gear Mesh Frequency = Shaft Frequency * Number of Gear Teeth
= 24.95Hz * 20
= 499Hz

Figure 10 shows the single vibration spectra, concentrating around the gear mesh peak to
measure the sideband activity in order to identify the problem and give a positive
recommendation.
Figure 10.




Gear Mesh Frequency @ 499Hz
STIL - S400T 28:1 GEARBOX
S/FLEET -G1H Shaft 01 Inboard Horizontal
Route Spectrum
15-Jul-03 09:46:18
OVERALL= .3927 A-DG
PK = .1598
LOAD = 100.0
RPM = 1498.
RPS = 24.96
400 440 480 520 560 600 640
0
0.03
0.06
0.09
0.12
Frequency in Hz
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Freq:
Ordr:
Spec:
Dfrq:
508.43
20.37
.02696
9.250
Sidebands measured at 9.25Hz
15

Sidebands indicate the rotational frequency of the offending gear.

Frequency of Shaft/Gear 2 = Gear Mesh Frequency / Teeth on Gear 2
= 499 / 54
= 9.24Hz

The sideband activity indicates the second gear to be causing the excessive gear mesh activity.
The backlash on this gearbox is set by shimming the second shaft along, thus adjusting the
depth of mesh between the gears. Because of this recommendations were made to check the
backlash and adjust if required.
On investigation the backlash was found to be out of tolerance and was reset.

Figure 11 shows a vibration waterfall plot taken from the input shaft of the gearbox. The data
in blue dated 24
th
July 03 showing a positive effect on the gearbox vibration after the backlash
was reset.

Figure 11.

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STIL - S400T 28:1 GEARBOX
S/FLEET -G1H Shaft 01 Inboard Horizontal
0 500 1000 1500 2000
0
0.01
0.02
0.03
0.04
0.05
0.06
0.07
Max Amp
.0603
13:24:41
24-Jul-03
09:46:18
15-Jul-03

Conclusion.
Had the excessive backlash not been detected and reset premature wear would have been
inevitable, reducing the service life of the gearbox.
The gearbox was to be fitted in an extremely awkward location once it had been transported to
site two miles underground, hence making the quality of the build paramount.







16

Testing of Equipment at the Original Equipment Manufacturer.

As part of our in house quality assurance procedures items of critical plant are vibration tested at
the Original Equipment Manufacture prior to being despatched.
When you consider the work involved in transporting the items of plant often weighing up to 15
tonnes down the mine shaft.




















Then transporting the machinery long distances often in excess of 5 miles to the coalface and
development areas of the mine. It is extremely important that the equipment leaves the O.E.M.
in perfect working order.

Ineffective Component Inspection Procedure, Highlighted using Emersons
PeakVue Technology.
The unit in question was a cutting head gearbox that had been overhauled at our own workshop
facility.
On an initial test run concerns were raised over an abnormal noise from the unit.
Standard vibration and PeakVue measurements were taken along the gearbox, aiming to
identify any potential faults, with concerns being raised around the third shaft.
Figure 12 shows a plan of the Cutting Head Gearbox.













G1
G3
G4
G5
G6
G7
G8
G9
G10
G11
G12
M1
M2
Faulty Gear
17

Figure 13 shows a single PeakVue Vibration Spectrum taken from shaft 3 of the gearbox.
Emersons PeakVue Technology works by filtering out background noise, looking at the high
frequency activity associated with metal to metal impacting.
The 1 order peak highlighted at 6.9Hz indicates an impact every revolution of the third shaft.
Figure13




















When the Time Domain data is analysed the true extent of the problem becomes apparent. A
severe impact can be seen every revolution of the third shaft.
Figure 14.






















When we referred to the standard vibration measurement, no activity of any significance was
recorded. The time waveform showed no signs of the once per revolution impact.
DTB - Boom Gear Box
BGB -G5P Shaft 03 Inboard Horz Peakvue
Route Spectrum
09-Jan-01 13:30:21
(PkVue-HP 1000 Hz)
OVERALL= 1.55 A-DG
RMS = 1.47
LOAD = 100.0
RPM = 415. (6.91 Hz)
0 40 80 120 160 200 240 280 320
0
0.1
0.2
0.3
0.4
0.5
0.6
Frequency in Hz
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Freq:
Ordr:
Spec:
6.914
1.000
.494
Freq: 6. 9Hz
Order: 1.00
Spec: .494
DTB - Boom Gear Box
BGB -G5P Shaft 03 Inboard Horz Peakvue
Route Waveform
09-Jan-01 13:30:21
(PkVue-HP 1000 Hz)
RMS = 2.14
LOAD = 100.0
RPM = 431. (7.19 Hz)
PK(+) = 14.25
CRESTF= 6.65
DCoff = -1.32
0 0.5 1.0 1.5 2.0 2.5 3.0
0
3
6
9
12
15
Revolution Number
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18
Figure15





















PeakVue Technology has proved extremely effective and reliable, helping us detect many low
frequency bearing problems and high frequency gear defects.
Because of the PeakVue data, recommendations were made to strip down and inspect the
gearbox, with the suspected fault being a damaged tooth on the third shaft assembly.

On inspection a crack was found at the root of the gear tooth as predicted. See figure 16.

Figure16.






Route Waveform
09-Jan-01 13:30:33
RMS = .1546
PK(+/-) = .5971/.5595
CRESTF= 3.86
0 1 2 3 4 5
-0.8
-0.6
-0.4
-0.2
0.0
0.2
0.4
0.6
0.8
Revolution Number
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DTB - Boom Gear Box
BGB -G5V Shaft 03 Inboard Vertical
Route Spectrum
09-Jan-01 13:30:33
OVERALL= .9308 V-DG
RMS = .2367
LOAD = 100.0
RPM = 431. (7.19 Hz)
0 300 600 900 1200 1500
0
0.03
0.06
0.09
0.12
Frequency in Hz
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19
This road heading machine is transported modular to the development area of the mine and then
assembled.
Had the gearbox been fitted it would have failed in a catastrophic manner, causing excessive
secondary damage to the gearbox as well as a delay to the development well in excess of 24
hours.

Figure17.














































20

Ineffective Component Inspection Procedure: Ranging Arm Gearbox.
My 2
nd
case study in this section again covers an ineffective component inspection on a Ranging
Arm gearbox.
Figure 18 shows a typical Retreat coal face.



With all the equipment being transported modular via a network of roadways before being
assembled at the coal face.
Figure 19.























Shearer
Powered Roof Supports
AFC
BSL
Gate
Conveyor
21

The gearbox in question drives from a motor via speed reduction and transmission gears, then
out through a epicyclic section to which the cutting disk is mounted. See Figure 20.
Various vibration measurements were taken along the gearbox to assess its condition.
Figure 20.


Figure 21 shows a single PeakVue Vibration Spectrum taken from the epicyclic section of
the gearbox, with excessive Gear mesh and sideband activity being present.

Figure 21.




EL60 - EL600-EL32A L/H RANGING ARM
EL32A RANG-10P Shaft 07 Inboard Horz Peakvue
Route Spectrum
09-Nov-04 11:51:46
(PkVue-HP 1000 Hz)
OVERALL= 1.80 A-DG
PK = 1.80
LOAD = 100.0
RPM = 552. (9.20 Hz)
0 200 400 600 800 1000
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
Frequency in Hz
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Typical Ranging Arm Gearbox.
Gear Mesh and Sideband Activity
22
Using the waterfall plot feature, the data was compared with the information collected from the
Shearers other ranging arm gearbox. See figure 22.
A significant difference in characteristic and amplitude can be seen.
Figure 22.


I calculated the frequency of the planet carrier with in the epicyclic to be 2.9Hz.

Reduction Calculation = 1 .
1-RO
RO = (Static Ring/Sun)+1
= (59 / 28) +1
= 3.1

Output Freq.(Planet Carrier)= Input Freq./ RO
= 8.98Hz / 3.1

Output Freq.(Planet Carrier)=2.9Hz




Using the software to manipulate the data the sidebands measured 2.9Hz. See figure 23
Sidebands indicate excessive clearance between the gear flanks. In this case the sidebands match
the rotational frequency of the planet carrier, which supports the planet gears.
In this instance the Epicyclic section wasnt new, but had been inspected and passed fit for use.



Figure 23.
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Frequency in Hz
EL60-EL600-EL32A L/H RANGING ARM EL32A RANG
EL60-EL600-EL32A R/H RANGING ARM EL32A (15-Nov-04)
0 100 200 300 400 500
0
0.05
0.10
0.15
0.20
0.25
0.30
0.35
Max Amp
.34
EL32A
EL32A RANG
L/Hand Ranging Arm
R/Hand Ranging Arm
23

Because the gearbox had always run in the same direction I carried out some tests running the
gearbox in the opposite direction, effectively driving on a new gear flank. See figure 24.
As anticipated the gear mesh and sideband activity were virtually non-existent.

Figure 24.
To prove the activity recorded wasnt a characteristic of running direction, further vibration tests
were carried out on the Shearers other ranging arm. See figure 25. With the same low levels of
activity being recorded in both directions.


Figure 25.


EL60 - EL600-EL32A L/H RANGING ARM
EL32A RANG-10P Shaft 07 Inboard Horz Peakvue
Route Spectrum
09-Nov-04 11:51:46
(PkVue-HP 1000 Hz)
OVERALL= 1.27 A-DG
RMS = .5974
LOAD = 100.0
RPM = 539. (8.99 Hz)
155 160 165 170 175 180 185
0
0.1
0.2
0.3
0.4
0.5
Frequency in Hz
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Freq:
Ordr:
Spec:
Dfrq:
172.27
19.16
.149
2.963
Sidebands at Rotational
Freq. of Planet Carrier
2.96Hz
Gear Meshing
Activity of
Sun/Planets
169.31Hz
Freq: 172.27
Ordr: 19.16
Spec: .149
Dfrq: 2.963
Right Hand Ranging Arm Direction Comparison
24
In my opinion the gearbox would not reach its intended design life if ran with the excessive
gear mesh activity present.
Because of this recommendations were made for the gearbox to be re handed before being put
into service, without any new components being required.

Changing out a ranging arm underground requires a considerable amount of hard work. If the
gearbox failed in service many production shifts would be lost.

Figure 26





























The old unit would have to be removed, with the new one was being transported to site and
fitted.












25
Figure 27 shows a coal face supply gate with excessive floor heave, making the transportation
of equipment to site difficult. Making an effective quality assurance procedure essential.




























BEARING FAULT DETECTION ON A CONVEYOR DRIVE MOTOR USING
VIBRATION ANALYSIS TECHNIQUES.

The R.C.M. Department at Rossington Colliery detected a bearing fault on the N.D.E. of the
above-mentioned Motor. After further investigation and analysis the Site Engineer was
advised that the motors N.D.E. bearing was in the final stages of failure and that the motor be
removed from service at the first available opportunity.
68s No3 Conveyor at the time was supporting coal clearance for one production coalface and
four tunnel drivages.
Figure 12 shows a Peakvue frequency based vibration spectra and a time domain waveform
collected from the non-drive end of the motor in question.
The frequency of the fault is showing at two times ball spin frequency.
The severity of the fault being judged by analysing the Peak to Peak Value in the time
waveform.
The average values recorded were in excess of 30gs Peak to Peak, an alarm level for this type
of fault at this operating frequency being 6gs Peak to Peak.




26
Figure 28.

Route Waveform
06-Jul-04 11:45:09
(PkVue-HP 1000 Hz)
RMS = 15.83
PK(+) = 58.51
CRESTF= 3.42
DCoff = 0.0
0 1 2 3 4 5
0
10
20
30
40
50
Revolution Number
A
c
c
e
l
e
r
a
t
i
o
n

i
n

G
-
s
68s3 - Drive 2
Drive2 -M1P Motor Outboard Horz Peakvue
Route Spectrum
06-Jul-04 11:45:09
(PkVue-HP 1000 Hz)
OVERALL= 7.09 A-DG
RMS = 7.05
LOAD = 100.0
RPM = 1496. (24.93 H
0 200 400 600 800 1000
0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
Frequency in Hz
R
M
S

A
c
c
e
l
e
r
a
t
i
o
n

i
n

G
-
s
Freq:
Ordr:
Spec:
132.77
5.326
3.403
>SKF N317
R=BSF -OB
R R R R R R R R R R R R R R R


Figure 29 shows a Waterfall Plot of Vibration data collected from the motor. The data in purple
showing the faulty bearing and the data in blue with a new motor fitted.

Figure 29.

R
M
S

A
c
c
e
l
e
r
a
t
i
o
n

i
n

G
-
s
Frequency in Hz
68s3 - Drive 2
Drive2 -M1P Motor Outboard Horz Peakvue
0 200 400 600 800 1000
0
0.5
1.0
1.5
2.0
2.5
3.0
Max Amp
3.00
09:02:36
14-Jul-04
11:45:09
06-Jul-04

27

On investigation severe Brinelling on both inner and outer raceways was found. The following
photographs show the Brinelling on the raceways at equal intervals to the rolling elements.

Figure 30 shows Brinelling evident on the outer race of the bearing.























Figure 31 shows Brinelling evident on the inner race of the bearing.




















28

Cost Benefit Analysis.

Production Cost Calculations.

1. Anticipated lost production time. 240 Mins
2. Rossington Face Cycle Time 42 Mins/Strip
3. Tonnes per Strip 614 Tonnes
4. Cost per Tonne 26.64

Figures calculated assuming no delays.

240Mins/42Mins per Strip 5.72 Strips
614 Tonnes * 5.72 Strips 3512 Tonnes
3512Tonnes * 26.64 93,559.68

Cost avoidance of potential Dangerous Occurrence !

Anticipated lost production time. 4 Hours 93,559.68
(Carry out on-site investigation,
pull back the motor after disengaging transmission)
Anticipated Repair Costs had Motor Failed 8126
in a catastrophic manner, less the quoted
repair.

Total 101685.68
Conclusion.

This bearing fault had shown no temperature increase, which is usually a good indication of a
bearing in failure mode. On researching this I have found that this type of bearing fault does
not generate any temperature increase until the bearing collapses.
Had a bearing of this type failed in service a risk of creating an ignition could have occurred.
In an underground environment this failure had the potential to cause a fire, putting many lives
at risk. Eighty per cent of underground fires are related to bearing failures, making a good
R.C.M. programme essential.


This paper has demonstrated how we can predict many different types of fault, all of which
required significant corrective actions to be taken.
What is of great benefit is to be able to detect something, which if left uncorrected has the
potential to cause a fault, which if diagnosed early enough requires no more than a lick of
grease or a drop of oil to prevent any fault developing.

The last case study covers the overhaul of a 90kW auxiliary fan at the O.E.M. The fan had
passed the O.E.M.s own quality assurance procedure before being sent out to Rossington
Colliery. The R.c.m. team at Rossington tested the fan as part of our own quality assurance
procedure. The fan motor failed the test due to excessive high frequency vibration, with the
suspected fault being a lack of lubrication at the drive end bearing.
The fan was sent back to the O.E.M. and Vibration data was collected from the Drive End
Bearing of the motor, with High Frequency Broad band Energy seen, see figure 32.

29

Fig.32.
16.2 - 90Kw FAN-150090
150090 -M2H Motor Inboard Horizontal
Route Spectrum
17-Feb-04 10:40:23
OVERALL= 1.47 V-DG
RMS = 1.83
LOAD = 100.0
RPM = 2978. (49.63 Hz)
0 1000 2000 3000 4000
0
0.04
0.08
0.12
0.16
0.20
0.24
Frequency in Hz
R
M
S

A
c
c
e
l
e
r
a
t
i
o
n

i
n

G
-
s

High Frequency Broadband Energy usually indicates a lack of lubrication. The drive end
bearing was greased, with small amounts being applied over a period along with further
vibration measurements being taken.

Eventually the Broad Band Energy reduced. The waterfall plot shows a considerable
improvement, with no permanent damage being recorded. See figure 33.

Figure 33.
R
M
S

A
c
c
e
l
e
r
a
t
i
o
n

i
n

G
-
s
Frequency in Hz
16.2 - 90Kw FAN-150090
150090 -M2H Motor Inboard Horizontal (17-Feb-04)
0 1000 2000 3000 4000
0
0.04
0.08
0.12
0.16
0.20
0.24
Max Amp
.23
12:44:41
17-Feb-04
10:40:23
17-Feb-04


High Frequency Broadband Energy
Indicating a Lack of Lubrication
30
Auxiliary fans are used to ventilate the development areas of the mine (see fig.34), this often
involves transporting the fan in excess of 5 miles to site. Because of the danger posed by a
bearing failing on a fan it is essential that the fans bearing condition is checked at
commissioning then monitored as part of a pro active Condition Monitoring Programme.
Figure 34.


























Equipment Change-out Summary 2005

So far 2005 has been a good year for the Condition Monitoring programme operated by U.K.
Coal, with approximately three hundred and thirty critical plant systems being monitored
within the R.C.M. programme on a two weekly schedule.
Throughout the year a over of 236000 vibration measurements will be taken with over 33000
oil samples being collected and analysed across the seven deep mine sites.
The table below shows a summary of plant items changed so far in 2005.

R.C.M. Technology. Planned Change. Unplanned Change
Vibration Monitoring 94 16
Oil Analysis 25 10
Both Technologies 33 11
Total Plant Items Changed 152 37

Many of the planned equipment changes were investigated with defective components found as
predicted.
Of the thirty seven unplanned changes over fifty per cent of the failures were reported as being
a cause for concern, but for various reasons were not investigated or the equipment
examination was rescheduled due to production demands.

31
Income Lost per Minute of Lost Production

Daw Mill 519
Harworth 262
Kellingley 468
Maltby 274
Rossington 274
Thoresby 310
Welbeck 246

When you consider the cost of lost production to us at U.K.Coal you will can understand why
we place great emphasis on operating an effective condition monitoring policy.



Condition Monitoring Statement.
Planned equipment changes do not interrupt production and early equipment change out
reduces the consequential cost of repair.
It is my opinion that if planned equipment change recommendations are ignored the item of
plant in question often makes the decision for you at a later date.



Cen-tech Ltd
Cen-tech Ltd is a wholly owned subsidiary of U.K.Coal Mining Ltd. We are using Cen-tech as
a vehicle to sell our Condition Monitoring expertise to third parties. We are able to offer a
wide range of Condition Monitoring services, including Vibration and Oil Analysis, Laser
Alignment and Thermographic Surveys.