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Protective Maintenance Fans Cement
 

Protective Maintenance Fans Cement

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Strategies for Vibration Monitoring, protective maintenance and other industrial fan related instruction.

Strategies for Vibration Monitoring, protective maintenance and other industrial fan related instruction.

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    Protective Maintenance Fans Cement Protective Maintenance Fans Cement Presentation Transcript

    • Strategies for Vibration Monitoring
      • The 4 “PM’s”
        • Preventive Maintenance
        • Predictive Maintenance
        • Proactive Maintenance
        • Protective Maintenance TM
      • Why Protective Maintenance?
      • Basic vibration
      • Fan applications
      • How much protection is enough?
      • Visit www.cbpowerandindustrial.com
    • Current Condition Monitoring Practices
      • Periodic monitoring using portable data-loggers
        • Usually “owned” by maintenance/contractor
        • Strong analytical tool: The masters of the “squiggly lines”
        • “ Spend 85% of their time on healthy machines” Heinz Bloch, Consultant
      • Full time protection from installed instrumentation
        • If installed at all, usually “owned” by operations
        • Very little knowledge of vibration expected or required of operators
        • Total installed cost is a factor in decision to protect or not
    • Protective Maintenance TM
      • Tearing down the (cement) walls between operations & maintenance
      • Combining the assets available for effective condition monitoring
        • Full time protection from installed instrumentation
          • Consider lower cost alternatives now on the market
          • Local indication (on protection device) & remote overall vibration trending
        • Pocket sized overall vibration meters for Operator to use on frequent rounds
        • Easy, safe data access for Analyst to diagnose faults and take corrective action
    • Benefits of adopting a program of Protective Maintenance TM
      • Get 24-7 real-time protection of important plant assets
      • Get operators more involved in the process of protecting their machines
        • Help operators quantify an important operating parameter
      • Call in vibration analyst (contractor) when needed
        • Complements existing condition monitoring programs
        • Analysts spend time more effectively on sick machines, not healthy ones.
      • Aids the analyst to get easy, safe access to dynamic data
        • Develops more consistency in the technique of data acquisition
        • Trends become even more valuable
      • Pays for itself and puts money to the bottom line
        • What is the value of one or two “saves” in a year?
    • Basic Vibration: simple yet complex or all an Operator needs to know about vibration
      • Sound: vibrating vocal chords
      • Overall sound level: LOUD or soft
      • Very complex: Bing or Sting; Bocelli or Minelli
      Light: from the sun Overall: Bright or dim Very complex: Prism Vibration: from rotating equipment: Overall vibration: High or low Very complex: Spectrum analyzers Orca’s sound pattern
    • Fan protection & condition monitoring in a “dry process” plant
      • Dry process plant synopsis
      rotary kiln raw mill electro-st precip coal mill sep sep sep electro-st precip cement mill sep cooler S t a c k S t a c k raw mill exhaust coal injection coal mill exhaust preheater exhaust cooler exhaust electroprecipitator exhaust cement mill exhaust cooler FD fan cooler recirculation
    • What are the most common Root Causes of Fan vibration? Significant frequency change mounting & foundation problems motor anomalies bearing wear Journal/sleeve “ anti-friction” misalign ment imbalance imbalance & other frequencies of interest Significant overall vibration change
    • Location on Fan for Monitoring Vibration
      • Ideally, on each bearing of a machine
        • Analysts typically take 9 readings per direct coupled machine
          • For analysis, 1- vertical & 1-horizontal per bearing & 1-axial per machine
      • “ If I take just one measurement, where is the best place on the machine?”
        • 1-horizontal on the inboard bearing cap of the driven equipment
        • This is also the best place to mount a single protection device
      1 3 4 2
    • Vibration Instrumentation for Protective Maintenance TM
      • Permanently installed protection monitors
        • Local or remote shutdown or alarm only
        • With local indication for operators
        • With 4-20 mA to DCS for trending
        • With easy access to dynamic data for the vibration analyst
      • Operators use a vibration meter on rounds
        • Machines “owned” by operations
        • Operators quantify overall vibration frequently; continuously
        • Machines seen frequently bringing 5 senses to bear
      • Analysts (maintenance) do periodic data collection & detailed analysis
        • Highly trained specialists with expensive tools
        • More time to spend on “sick” machines
        • More time for proactive work
    • “ How much protection is enough for your operation?”
      • First, Decide on a strategy that suits your operation
      • Assume “Protective Maintenance” suits your needs
        • Start “teaming” operations & maintenance up front
        • Classify your machines
            • Critical - Important - Balance Of Plant (BOP)‏
        • Plan to install vibration monitoring instrumentation on all critical machines
          • Dedicated monitor, multi-machine monitors, transmitters to your PLC/DCS
        • Consider installing monitors or switches on important machines
        • Outfit operators with “pocket” vibration meters for use on rounds
        • Analysts to establish a simple technique & set expectations with the operators
          • Where & how to measure vibration on each machine: mark the machines
          • Optional operator logging procedure
      • Use a capital project to get all or part of the solution
        • Use incremental methods for all or part & e ase into budget & sign-off issues