Condition Based Maintenance

An Overview
PDC Engineering
What is CBM?
 A maintenance strategy that is based on
maintenance being carried out as and
when the equipment requires it.
 Other strategies are:
 Run to failure.
 Hours or calendar based.
How do we know when to do
maintenance using CBM?
 By taking measurements which will infer
the condition of the machine
 Measurement types include:
 Vibration analysis
 Infrared thermography
 Passive ultrasound
 Tribology
 Process – temperature, pressure etc
We want to monitor the
condition of our machinery

 How do we start?
 We carry out a
POTENTIAL FAILURE ANALYSIS
PFA for an electric motor
Press Main Drive Motor PFA Tree
External
Base Cause Failure Type Parameter The
Technology applicableInterval
Analysis parametersSet Up
Manifestation In the last column we specify
Using our experience, we
For example, spalled We then This example
identify for
how will
detecting
that require spalled bearings
We first
Bearing decide what the some
The of the
detection finer detailsnow
of spalled to
On Linedecide
Fmax =onBPFIthe
x 8 specifics
Dry/Marked Failure High frequency
bearings
Vibration
will lead
failure a measurement
Demodulation
to mechanism are
will based
Spikes velocity
@ Brg defect
show on spectrum and
bearings resonance
possible failuresdefectcould
@ bearing
beintervals bearings ensure
(Ultra Sound) good,bepractical
should
frequencies (20
carried
dBG) Radial
when carrying out the analysis
frequency
a bearing failure a vibration
itself as something we See
can time
sect. 2.5 waveform in G’s
technology
measure
G acceleration
out
Time failure
continually detection
(On-Line)On Line = 3 revs
Peaks in waveform
Waveform
Spalled Bearing Failure Harmonics of bearing Vibration Velocity Spikes @ Brg defect On Line Fmax = BPFI x 8
bearings defect frequencies freqys. & harmonics (higher if not using
and/or sidebands. resonance parameter)
See sct. 2.5 Radial

Time Peaks @ 12 G (roller) On Line = 3 revs

Waveform 7 G (ball brg) G acceleration

Misalignment Bearing Failure/ High axial vibration Vibration Velocity Multiples of run speed On Line Fmax = 10 x rpm
Shaft Failure axial > radial Axial

Looseness Bearing Failure/ Run speed harmonics Vibration Velocity Multiples of run speed On Line Fmax = 10 x rpm
Shaft Failure/ & subharmonics up to 15x. Possible Vertical
Structural Failure sub-harmonics

Bad S.C.R.s Reduced Power Vibration @ SCR Frqys Vibration Velocity 240 Hz, 1/3 DC pulse, On Line Fmax = 120 kcpm
Motor Burnout s/band on DC(Sect.2.5) Drive End
Changes in SCR temps. Thermography Thermal Image Bad SCR is colder 6 month Compare SCR to SCR
Different current / Current Draw Amps Unbalanced supply 6 month Compare phase to phase
input phase
Winding Motor burnout Stator temp. rise/ Thermography Thermal image Hot spot on stator 6 month 1 baseline
defects Uneven temp. distribution (spot temp)

Earth current leakage Insulation test Megger Should be > 1.5 M 6 month Motor de-energized

Rotor Rotor failure Line frequency + Motor load Motor current Sidebands of slip x No. 6 month Press idling
defects sidebands current analysis frequency of poles around 60 Hz
(Sect. 2.2)
Motor burnout Vibration @ rotor bar Vibration Velocity Sidebands of 1x On Line Fmax = RBPF x 3
pass frequency (Sect 2.2) Radial
c. Ron Frend - PreDiCon
 100 HP AC Motor PFA Tree
External
Base Cause Failure Type Technology Parameter Interval Detail
Manifestation

Dry/Marked Bearing Failure

bearings

Spalled Bearing Failure

bearings

Misalignment Bearing Failure/

Shaft Failure

Looseness Bearing Failure/

Shaft Failure/
Structural Failure

Winding Motor burnout

defects

Rotor Bearing failure

defects

Motor burnout
 100 HP AC Motor PFA Tree
External
Base Cause Failure Type Technology Parameter Interval Detail
Manifestation

Dry/Marked Bearing Failure High frequency resonance

bearings @ bearing defect
frequency intervals

Spalled Bearing Failure Harmonics of bearing

bearings defect frequencies

Misalignment Bearing Failure/ High axial vibration

Shaft Failure

Looseness Bearing Failure/ Run speed harmonics

Shaft Failure/ & subharmonics
Structural Failure

Winding Motor burnout Stator temp. rise/

defects Uneven temp. distribution

Earth current leakage

Rotor Bearing failure Line frequency +

defects sidebands

Motor burnout Vibration @ rotor bar

pass frequency
 100 HP AC Motor PFA Tree
External
Base Cause Failure Type Technology Parameter Interval Detail
Manifestation

Dry/Marked Bearing Failure High frequency resonance Vibration Enveloping

bearings @ bearing defect (HFD/B)
frequency intervals (Shock Pulse)
(Ultra Sound)

Time Waveform
Spalled Bearing Failure Harmonics of bearing Vibration Velocity
bearings defect frequencies

Time Waveform

Misalignment Bearing Failure/ High axial vibration Vibration Velocity

Shaft Failure

Looseness Bearing Failure/ Run speed harmonics Vibration Velocity

Shaft Failure/ & subharmonics
Structural Failure

Winding Motor burnout Stator temp. rise/ Thermography Thermal image

defects Uneven temp. distribution (spot temp)

Earth current leakage Insulation test Megger

Rotor Bearing failure Line frequency + Motor load Motor current

defects sidebands current analysis frequency

Motor burnout Vibration @ rotor bar Vibration Velocity

pass frequency
 100 HP AC Motor PFA Tree
External
Base Cause Failure Type Technology Parameter Interval Detail
Manifestation

Dry/Marked Bearing Failure High frequency resonance Vibration Enveloping 1 month

bearings @ bearing defect (HFD/B)
frequency intervals (Shock Pulse)
(Ultra Sound)

Time Waveform 1 month

Spalled Bearing Failure Harmonics of bearing Vibration Velocity 1 month
bearings defect frequencies

Time Waveform 1 month

Misalignment Bearing Failure/ High axial vibration Vibration Velocity 3 month

Shaft Failure

Looseness Bearing Failure/ Run speed harmonics Vibration Velocity 1 month

Shaft Failure/ & subharmonics
Structural Failure

Winding Motor burnout Stator temp. rise/ Thermography Thermal image 6 month
defects Uneven temp. distribution (spot temp)

Earth current leakage Insulation test Megger 6 month

Rotor Bearing failure Line frequency + Motor load Motor current 6 month
defects sidebands current analysis frequency

Motor burnout Vibration @ rotor bar Vibration Velocity 3 month

pass frequency
 100 HP AC Motor PFA Tree
External
Base Cause Failure Type Technology Parameter Interval Detail
Manifestation

Dry/Marked Bearing Failure High frequency resonance Vibration Enveloping 1 month Fmax = BPFI x 3
bearings @ bearing defect (HFD/B) Radial
frequency intervals (Shock Pulse) G acceleration
(Ultra Sound)

Time Waveform 1 month = 3 revs

Spalled Bearing Failure Harmonics of bearing Vibration Velocity 1 month Fmax = BPFI x 3
bearings defect frequencies (higher if not using
resonance parameter)
Radial

Time Waveform 1 month = 3 revs

G acceleration

Misalignment Bearing Failure/ High axial vibration Vibration Velocity 3 month Fmax = 4 x
Shaft Failure Axial

Looseness Bearing Failure/ Run speed harmonics Vibration Velocity 1 month Fmax = 4 x
Shaft Failure/ & subharmonics Vertical
Structural Failure

Winding Motor burnout Stator temp. rise/ Thermography Thermal image 6 month 1 baseline
defects Uneven temp. distribution (spot temp)

Earth current leakage Insulation test Megger 6 month Motor de-energised

Rotor Bearing failure Line frequency + Motor load Motor current 6 month Motor running
defects sidebands current analysis frequency > 1/2 load steady

Motor burnout Vibration @ rotor bar Vibration Velocity 3 month Fmax = RBPF x 3
pass frequency Radial
How do I start?
 First define your PFAs
 Decide on applicable technologies
 Decide on measurement intervals
 Decide on measurement strategy
 Maintain copies of PFAs for ISO 9002
audit compliance
Applicable Technologies
 Vibration Analysis
 Infrared Thermography
 Passive Ultrasound
 Tribology
Vibration Analysis
 On Line or Off Line?
 How long is the failure mechanism?
 Will the machine always run at measurement
time?
 Does the machine run under consistent
conditions?
 Is access safe?
 Is access convenient?
 Rule of thumb
 Use on-line for process critical or high capital cost
equipment
 Use off line for spared or non-critical equipment
The Failure Mechanism
 Example:
 A bearing on a large slow moving fan may last for
a year after the onset of lubrication failure.
 A bearing on a pump may only last 2 days
depending on load, speed, alignment, initial
lubrication etc.
 Remember:
 Vibration will only detect defects that exhibit a
measurable difference prior to failure.
 Vibration WILL NOT detect fatigue or stress
failures in advance as there is no external change
to influence the vibration parameters.
Run Conditions
 Modern on-line systems can store data in
separate locations for different running
conditions (load, speed etc).
 On-line systems should not store data when
the equipment is not running.
 Remember the value of a vibration analysis
system is in the DATA – NOT the equipment.
On-line gives full value continually.
Vibration examples
 Mill gearboxes
 Lauter Tun drives
 General examples
Mill Crankshaft Gearboxes
 Mill #2 Drive Gearboxes
 Top/Middle/Bottom
 8th of July 1999 at 8:16
am
Lauter Tun Gearboxes
 Lauter Tun 1 (red)
 Lauter Tun 2 (blue)
 Output Shaft
 31st January 2002
 General Examples

 Imbalance  Looseness

 Bad Bearings
Infrared Thermography
 Non contact
 Non intrusive
 Radiometric capability
 Images stored for history
 Infrared Thermography
Electrical Example

74.1°C

70

60

Terminal: 74.6°C
50

40
39.1°C

Boiler Primary 46B/75

20th October 2000
 Infrared Thermography
Mechanical Example

66.6°C

60
Mtr D/E Brg: 66.9°C
Mtr Body: 50.1°C

Pump Brgs: 35.4°C

40

20

8.3°C

Brine Fixed Speed Pump 53C/007

20th October 2000
Passive Ultrasound
 Trouble shooting
 Bearings
 Air leaks
 Hydraulic valves
 Steam traps
Passive Ultrasound

Ultrasound Ultrasound
recording of a recording of a
good bearing bad bearing
Tribology
 Very early warning of defects
 Most useful in hydraulic systems
 ISO cleanliness or SOAP
 Spectrographic Oil Analysis Progamme
 Oil Analysis SOAP Trend
Alarms 15/09/1994 05/11/1994 01/12/1994 26/01/1995 14/04/1995 16/05/1995 07/07/1995 17/08/1995 06/10/1995 16/11/1995 26/12/1995 19/01/1996
Iron 13.0538793 11 12 7 10 10 8 8 11 6 9 12 4
Copper 8.833227979 8 8 5 5 6 5 6 8 5 170 186 47
Viscosity 266 268.4 272.5 273.2 273.5 274 275 275.3 272.6 274.7 281.2 275.8
Oxidation 1 0 0 0 1 0 1 1 1 0 2 0
Silicon 1 0 0 0 1 0 0 0 0 0 0 0
Lead 0 0 0 0 0 0 0 1 0 17 20 4
Oil Rating Sat Sat Sat Sat Sat Sat Sat Sat Sat Sat
Changed
Filters 05/01/1996
Temp(fluid) 79
Temp(pmp) 95

450 A OIL ANALYSIS

200
180
160
PARTS PER MILLION

140
120
100
80 Iron

60 Copper

40
20
0
Alarms 15/09/1994 05/11/1994 01/12/1994 26/01/1995 14/04/1995 16/05/1995 07/07/1995 17/08/1995 06/10/1995 16/11/1995 26/12/1995 19/01/1996
Ferrography

Microscopic analysis of oil samples

ISO Cleanliness Codes
CLEANLINESS LEVEL CORRELATION TABLE
P articles NAS 1638
per ml>10 (1964)
ISO CODE microns
21/18 4500
(1963)
12
SAE Level
-
Particle count testing provides a
20/18 2400 - - determination of the number of
20/17 2300 11 - particulates in a specific size range
20/16
19/16
1400
1200
-
10
-
-
Normal Operating Cleanliness using the International Standards
Levels (unfiltered oil)
18/15 580 9 6 Organization (ISO) Cleanliness
17/14
16/13
280
140
8
7
5
4
Approximate New Oil
Code, ISO 4406. An ISO Code is
created by selecting three ISO range
15/ 12 70 6 3
Critical Cleanliness
numbers that correspond to the
14/ 12 40 - -
14/ 11 35 5 2
Range (critical
hydraulic units)
number of particles in a milliliter of
13/10 14 4 1 fluid greater than 2, 5, and 15
12/09 9 3 0
11/08 5 2 -
microns, respectively.
10/08 3 - -
10/07 2.3 1 -
10/06 1.4 - -
09/06 1.2 0 -
08/05 0.6 0 -
In-House or Outsource?
 This must be your decision based on:
 Cost
 Available manpower
 Training commitment
 Ownership strategy
Define A Project
 Whichever method you choose, treat
the installation of CBM as a
maintenance project
 Define targets, milestones and
resources
 Measure your progress and report
regularly
The Project Timeline
End Points
 Be consistent
 Have a clearly defined reporting
strategy
 Report your cost savings regularly
 IF IT ISN’T SAVING YOU MONEY IT’S
NOT WORTH DOING