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  • 1. Early detection of machinery failures using onlineCondition Monitoring Systems (CMS)PRUFTECHNIK Middle East FZE (Dubai) / Robert Schmaus / 28-04-2013
  • 2. 27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 2
  • 3. 22/03/2012PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 3
  • 4. 27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 4Agenda- Content►Brief company profile►Introduction to CM►A typical plant►Machine health monitoring►CM technologies►Level 1 & Level 2 strategy►The right measurement tools►Is online monitoring needed?►Case studies►Examples of online CMS installations►Summary
  • 5. COMPANY PROFILEPRUFTECHNIK27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 5
  • 6. PRÜFTECHNIK Group facts► Location of headquarter: Ismaning (Munich), Germany► Divisions:● PRÜFTECHNIK Condition Monitoring GmbH● PRÜFTECHNIK Alignment Systems GmbH● PRÜFTECHNIK NDT GmbH (Nondestructive Testing)► Founded in 1972 by Dieter Busch► PRÜFTECHNIK Group CEO: Dr. Sebastian Busch► Activities:● Research & Development● Production● Sales and service of electronic and electrical instruments,especially measurement and control systems.► Patents & Trademarks: 300 patents & 150 trademarks worldwide► Quality Management: ISO 9001 since 1994► Staff: approximately 550 employees► Sales turnover 2012: approx. 70 millions EURO► Sales Channel Network in over 70 countriesPRÜFTECHNIK general HQs in GermanyDieter Busch Dr. Sebastian Busch27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 6
  • 7. Worldwide sales channel network PRÜFTECHNIK maintains an international sales networkcovering more than 70 countries27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 7
  • 8. PRÜFTECHNIK – a reliable long-termpartner Since the foundation of PRÜFTECHNIKin 1972, the company has maintained areasonable growth of sales turnover,company organization and employees. PRÜFTECHNIK invests over 15% of itsannual sales turnover in R&D and everyyear in order to ensure productenhancements and development of newproducts. Today more than 80% of the turnover isachieved with products which are nomore than 4 years old. A substantial role in this is played bythe development department which stillmakes up 25% (a quarter!) of theworkforce.The high export quota of approx. 80% isa distinguishing feature of technicallyqualified products27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 8
  • 9. Main product launches for ConditionMonitoring1980 VIBROSPECT®1980 VIBROCORD® 11989 SYSTEM 21992 X-Tector1993 VIBROTIP®1995 VIBCODE®1996 VIBRONET®1997 VIBREX®1998 VIBROCORD® 21999 VIBRONET® Signalmaster2000 VIBSCANNER®2003 smartSCANNER®2004 VIBROWEB®2004 VIBXPERT®2005 VIBROWEB® XP2005 VIBNODE®2009 WearScanner®2010 VIBXPERT® II2011 VIBCONNECT®2012 VIBGUARD®VIBROSPECT® VIBROCORD® 1SYSTEM 2®VIBROCORD® 2 VIBSCANNER® smartSCANNER®VIBXpert® IIVIBXpert® EXVIBXpert®27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 9
  • 10. PRUFTECHNIK awardsYear Product Award2010 VIBXPERT® II Product of the Year 2010 – Winner (Inżynieria i Utrzymanie Ruchu)2010 VIBXPERT® II Product of the Year 2010 – Finalist (Plant Engineering Magazine)2010 VIBXPERT® II TOP 2 in 2010 IMPOvation Awards2010 VIBXPERT® II Honorable Mention in the 2011 / AHR Expo Innovation Awards Competition2010 VIBXPERT® II Breakthrough Product of 2010 (Processing Magazine)2010 VIBXPERT® II Product Innovation of the Year – 4th place (Pumps & Systems)2010 PARALIGN® Industriepreis 2010 (Huber Verlag für Neue Medien)2009 INCLINEO® Breakthrough Product of 2009 (Processing Magazine)2009 INCLINEO® Product of the Year 2009 – Finalist (Plant Engineering Magazine)2009 ROTALIGN® Ultra IMPOvation product technology award (IMPO Magazine)2008 VIBXPERT® EX Product of the Year – Finalist (Plant Engineering Magazine)2008 OPTALIGN® smart Designpreis 2008 Nominee (Designpreis der Bundesrepublik Deutschland)2007 PARALIGN® Technology of the Year Award (AIMCAL)2007 PARALIGN® Matteucci Award Winner (AIMCAL)2007 OPTALIGN® smart Product of the Year – Gold Award (Plant Engineering Magazine)2007 OPTALIGN® smart red dot design award (Design Zentrum Nordrhein Westfalen)2007 OPTALIGN® smart Product of the Year – Finalist (Plant Engineering Magazine)2006 ROTALIGN® Ultra Product of the Year – Silver Award (Plant Engineering Magazine)2005 PARALIGN® Palme d’Or des trophées de l’innovation 2005 (ATIP)2005 ROTALIGN® Ultra Best of NED Problem-Solver (New Equipment Digest (NED))2005 ROTALIGN® Ultra Breakthrough Product (Processing Magazine)2003 smartSCANNER® Product of the Year – Finalist Plant Engineering Magazine)2003 smartSCANNER® Breakthrough Product (Processing Magazine)2002 VIBSCANNER® Product Of the Year Award (Fluid Handling Systems Magazine)2001 VIBSCANNER® Product of the Year – Gold Award Plant Engineering Magazine)2000 VIBSCANNER® Roter Punkt für Hohe Designqualität Design Zentrum Nordrhein Westfalen1997 OPTALIGN® PLUS Product of the Year – Silver Award (Plant Engineering Magazine)1996 OPTALIGN® PLUS IF Product Design Award (Industrie Forum Design Hannover)1993 VIBROTIP® Roter Punkt für Hohe Designqualität (Design Zentrum Nordrhein Westfalen)1992 TURBALIGN® Product of the Year – Bronze Award (Plant Engineering Magazine)27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 10
  • 11. 04/02/2013PRUFTECHNIK Middle East FZE (Dubai) - Robert Schmaus 11Some of our target marketsOil & Gas Off Shore PowerWindMarineChemical Paper / FilmsSugarTextileCementMiningSteelWaterServicesAutomotive
  • 12. Some worldwide references27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 12FEWA - United Arab Emirates
  • 13. 27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 13Introduction
  • 14. 27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 14Predictive Maintenance helps to► Increase machine reliability► Ensure machine availability► Secure productivity► Decrease maintenance costs► ... And finally helps to optimize profitsIncrease profitability in your plantYearsProductivityCostsPROFIT
  • 15. 27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 15TimeWhy CM?Startingpoint of afailureEvolutionintovibrationWearparticles inoilIncreasednoiseHeatdevelopmentFunctionalfailure CM shows the optimal time for intervention on machines
  • 16. 27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 16Example of a successful CM pilot project CM Vibration Analysis concept was started in 1990. The concept was realizedin 1991 and covered approximately 250 pumps. Usually 100 maintenance stops were required due to failures on pumps Main problems were the bearings Anual repair costs: 160,000 USD (without production losses, etc) After implementation of a CM strategy the number of repairs per yeardecreasedNumberofrepairs
  • 17. 27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 17A typical plant
  • 18. 27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 18So... how are your machines doing?ConveyorsKilnCooler PrehomogenizationRaw material storageRoller MillPacking Cement siloQuarryCrusherPreheaterClicker siloCement mills Raw meal homogenization124357891011121314You know how your production is doing. Fine. But what about the health of each machine involved in production?6Simplified example of a cement plant
  • 19. 27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 19So... how are your machines doing?ConveyorsKilnCooler PrehomogenizationRaw material storageRoller MillPacking Cement siloQuarryCrusherPreheaterClicker siloCement mills Raw meal homogenization124357891011121314Condition monitoring allows to detect problematic machines before a damage unexpectedlyinterrupts the production processCondition monitoring tools identify machines at an early deterioration stage and classifies theminto different categories reflecting severity of healthGREEN = long term operation is OK / YELLOW = restricted operation allowed / RED = machine didrun into alarm status; must be stopped immediately6
  • 20. 27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 20Machine healthmonitoring
  • 21. 27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 21Breathing frequencyCondition Monitoring = Health MonitoringBreathing trendOxygen trendVein pressure trendArterial blood pressure trendElectro cardiogram trendOxygen in bloodValues ofartificialrespirationCentral vein pressureBlood pressureAlarms Heart rate- Applied to human being  health monitoring► Measuring parameters such as blood pressure, temperature, etc► Trending values when required► Analyzing changes over timeControl panelTRENDSVALUES
  • 22. 27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 22Condition Monitoring?- Monitoring machinery health► DEFINITION: Condition monitoring is the process of monitoring parameter ofmachinery health or machinery condition, such that a significant change isindicative of a developing failure.► Rotating machinery reveales its condition via parameters such as:● Vibration● Temperature● Oil samples● Sound● Motor current● Etc► Such machine parameters are measured with the aid of diverse technologies
  • 23. Condition Monitoring technologies27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 23Infrared thermography19%Oil analysis14%Other9%Ultrasound7%Motor currentanalysis3%Vibrationanalysis48%Process parameters ≠ condition monitoring parameters
  • 24. 27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 24Level 1 and Level 2strategy
  • 25. 27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 25Level 1 & Level 2Level 1 Where is the problem?Detection of machines with problemsLevel 2 What is the problem?Analysis: finding the root cause ofproblemsExample:Level 1 measurements detect changes in the machineconditionMeasurement value trends increased over a time periodChanges in machinery health occur: vibration levels arehigher, machine condition is deterioratedExample:Analysis of FFT spectra and envelope spectraFind source of problems e.g. unbalance,misalignmentDiagnose and correct problem, e.g. balance rotor,align machine shaft, etc
  • 26. 27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 26Level 1 & Level 2Level 1DetectionLevel 2AnalysisExample:Performing vibration measurements periodically allowsto detect a machine with poor conditionVibration levels increased compared to previousmeasurementsMachine condition is clearly deteriorated – but why? Level 2Overall value measurement trendExample:Analysis of FFT spectra and envelope spectraFind source of problems e.g. unbalance,misalignmentDiagnose and correct problem, e.g. balance,align machine shaftVibrationvaluetimePrewarning levelAlarm levelWarning level
  • 27. 27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 27Typical Reliability based Maintenance work flowDefine and perform measurementsof Level 1 & 2, depending on themachine and the typical failuresexpected to be detected (fast failureevolution / online measurements /Offline measurements / etc.)Detection: trending of collectedmeasurement data of overall values.Intelligent alarming is required here.(Level 1)Analysis: when relevant changesoccur to the values in the trends,analyze Level 2 measurementsDiagnostic: based on theinterpretation of Level 2measurements, formulate adiagnostic and actionCorrection: select the appropriatecorrection method to correct thefailure and eliminate the failure rootcause*1) DEFINITION2) DETECTION3) ANALYSIS4) DIAGNOSTIC5) CORRECTIONExample gearbox: RPM, bearingtypes, number of teeth, number ofstages, etc.Example: elevated overall vibrationvalue on motor drive sideAnalyze the increased vibration peaksand the characteristic frequencies : 1x,2x, gear mesh = RPM x number ofteeth, etc.Diagnose and describe the failure as perLevel 2 measurements – formulate theroot cause of failuresMisalignment  align with laser alignmentImbalance  perform dynamic filed balancing*After the correction phase, it is necessary to recheck the machine conditionagain, to ensure that there is a real vibrational enhancement of the machine
  • 28. 27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 28The rightmeasurement tools
  • 29. 27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 29Tools used for vibration analysis- Condition monitoring / vibration analysis► Vibration data collectors can be:● Portable data collector and analyzer■ Mobile instrument and sensors■ Fixed installed sensors connected to junction boxes● Online Condition Monitoring Systems (online CMS)● Machine protection► Powerful software platform:● Storage of collected measurement data● Analysis and diagnosis of problems● Reporting capabilities● Interface to e.g. CMMS (SAP, Maximo) etc
  • 30. 27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 30Offline measurements
  • 31. 27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 31Portable data collector (offline) 1Manual data collection withportable instrument on alarge number of machinesMachine (pump)Measurementsensors attached tomachines viamagnetic basesCollected data isstored on asoftware platform(database),analyzed andprinted into reportsVIBXpert® II instrument
  • 32. 27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 32Portable data collector (offline) 2- Junction box (“SwitchBox”)► Permanent sensors mounted on machines are connected to junction boxes► Data is still manually collected but from a safe location► Ideal for machines in hazardous or restricted areas► Faster data collection than with mobile sensor and data collector
  • 33. - Multiplexer support(Automatic Switchbox)…- just a step beforeimplementation of online CMS27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 33
  • 34. 27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 34► Concept of a standard (manual)switchbox:● safe, reproducible and reliablemeasurement of● remote or hard to reachlocations► VIBXPERT® II multiplexer support:● The above features PLUS● Automatically switching throughthe channels – up to 54 per line● "One click measurements"→ click once – have a coffee ► A time saving feature for safe,reliable and fast measurements► First step towards implementation ofonline systems (CMS)…Intelligent MUX measurementsVIBXpert® II instrument
  • 35. 27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 35► The feature can also be used inintrinsically safe environment► All that is needed is the ATEXversion of the multiplexers,sensors, cables…► … and a limiting device.► The instrument connects then inthe non-EX area and enters theATEX area via the limiting deviceVIB 3.550LimitingdeviceMultiplexor VIB 8.306EX* with accordingsensor cards(VIB 8.314EX for ATEXvibration sensors)Vibration sensors VIB 6.122DEXIntelligent MUX measurementsVIBXpert® II instrument
  • 36. 27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 36Online ConditionMonitoring systems(CMS)
  • 37. 27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 37Online data collection Sensors are permanently mounted on critical machines Online CMS automatically collects data and handles alarms Monitoring ‘around the clock’Simplified example of a cement plantDatabaseSensors& OnlineCMSLAN /EthernetInternet
  • 38. RPM, temperature, processparameter,etcSample main functions of an online CMSVIBNODE®online CMSSwitch offCommunicationwith DCS / SCADAVia FiledbusMeasurements, alarms, etc.MACHINE PROTECTION PREDICTIVE MAINTENANCEPLCOMNITREND®Software PlatformLAN / EthernetSENSORSCABLES27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 38
  • 39. CMS interfaces and functions (examples)LAN/Ethernet12 analog inputs(e.g. accelerometers) 2 RPMsignals2 digital inputs(“trigger” for turn on/ turn off themachine) TTL 5V…+30VControl roomVisualization of themeasurement resultsExample: Profibus, ModbusControl panelVisualisation of themeasurement resultse.g. stop of machineOptional (VIB 7.112)Two outputs 4-20mA3 digital outputs+30V / +0.1Ae.g. Acustic alarmse.g. visual alarmse.g. For stopping the machine(*it is not a protection system)RS232/1 serial communicationWireless Transfer ofmeasurement data andaccess toCMSNotebookRS232/2 serial communication(System Fieldbus: Modbus, Profibus)SPC/PLC27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 39
  • 40. Sample online CMS architectureMeasurementsProcessingStorageCommunicationVIBNODE®VIB 7.150-SET-SOAnalog inputs 1 to 12, configurable as standard per jumper toalso ICP (voltage) sensors, +/- 5V or +/- 20 mA.Digital inputs:Analog inputs:Power supply.:A_1-BA11101 analog input 1A_2-BA11102 analog input 2A_3-BA11103 analog input 3A_4-BA11104 analog input 4A_5-BA11105 analog input 5A_6-Bn11106 analog input 6A_7-BA11107 analog input 7A_8-BA11108 analog input 8A_9-BA11109 analog input 9A_10-BA11110 analog input 10A_11-BA11111 analog input 11A_12-Bn11112 analog input 12N_1-BN11201 Puls/RPM 1N_2-BN11202 Puls/RPM 224V230VAC / 24V DC 24 V-Switch24VSW+-BD11205 System OK (FET)SYS-FET-BD11206 Digital output 1OUT_1-BD11207 Digital output 2OUT_2-BD11208 Digital output 3OUT_3Digital outputs:Ethernet TCP/IPRJ45, 10MBit/sEthernetCommunication:Interface relayPower supplyVIB 5.964-0,8(optional)Phone connection analog /GPRS (optional)RS 232/1Fieldbus Profibus-DP(optional) or other ‘protocolconverter’. Otherconverters available uponrequest.RS 232/2Fieldbus-ModuleVIB 5.920-PDP(optional)ModemVIB 5.93x-xxx(optional)Cabinet IP65 (Larger cabinet dimensions: approximately 300 x 200 x 130 mm)IN_1-BD11203 Digital input 1IN_2-BD11204 Digital input 2Interface relayInterface relayInterface relay27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 40
  • 41. OMNITREND® software platformRepresentation of machines,including measurementpoints and measurementtasks, with individualsettings for each point andtasksVisual detection of alarmshighlighted with colored flags :red (alarm), yellow (warning), etc.Problem analysis, diagnosticand identification of the rootcause of problemsSetting of narrow-bandalarms (etc) for accuratefault monitoring anddiagnostic trends allowpredictive view of health ofmachines.OMNITREND® is used alsoto configure all tasks etc. inthe online CMS.27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 41
  • 42. 3-D Spectra, waterfall diagram27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 42
  • 43. CMS in action in water plant in GermanyVIBNODE® CMS interior (example)VIBNODE® Online CMS (large cabinet)Vibration sensors**Location and number of sensor varies depending on machine characteristics27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 43
  • 44. SENSOR INFORMATIONA SHORT OVERVIEW**) for additional information please refer to existing documentation such as but not limited to brochures, catalogs, manual, technical notes, etc.27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 44
  • 45. 27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 45TANDEM-Piezo®, the 2-in-1 sensorCoverage of standardvibration frequencies(range e.g. 1Hz – 20kHz))1) VIBRATION 2)BEARINGCONDITIONPUMPCAVITATIONCoverage of higherfrequencies(sensor resonance @ 36kHz)ATEXoption
  • 46. Options for mounting sensors onmachinesOption 1:Type VIB 6.1xx sensor with90° base screwed directlyonto machineOption 2:Type VIB 6.1xx sensor with90° base screwed intoadapter which is bondedonto machineOption 3:Type VIB 6.1xx sensor withflat base bonded directlyonto machineScrew-in sensorBonded adapterBonded sensor Screw-in sensor27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 46
  • 47. Examples of bonded adaptersICP typeCLD type CLD type27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 47
  • 48. Typical mounting of CLD vibration sensorClamp VIB 6.720Clamp VIB 6.721Protective cap VIB 6.700Sensor VIB 6.122 typeDust cap sleeve VIB 6.722The VIB 6.122 accelerometersensors can be1) screwed into drilled/tappedholes – or – 2) screwed onadapters as this one; adapter onlyis bonded to the machine.Or, 3) additionally special“bonded sensors “(mounted withspecial glue/Loctite) can bemounted without drilling themachine e.g. VIB 6.102R sensors.Different cable options for EXor non-EX areas27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 48
  • 49. Accelerometer sensor VIB 6.122R / VIB 6.122 DEX* CLD typeDimensionsMounting instructions*Instead of threaded sensors, bonded sensors available on request!27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 49
  • 50. 27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 50When do I need onlineCMS?
  • 51. 27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 51Offline measurements cannot detectintermittent problemsBut I already measuredthis machine and did notfind any irregularities...!!!**Hmm... How to find problems that do no show up while performing offline measurements?
  • 52. 27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 52100% of all machines inthe plantAWhy online? “ABC Analysis”Do I need to monitor all machines with online CMS? Less relevant machines, low or none impact on production  C Critical machines (also auxiliary critical machines!)  B Very critical machines for production  AB C
  • 53. 27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 53OnlineprotectionsystemsRoutine inspectionsWhy online? The right CM toolCosts–lossofproduction,etc(*time till failure / time between measurements)$$$$$$Deterioration Sudden failuresMeasurementswith portable datacollectorsOnline ConditionMonitoringmonths weeks days hours minutes secondsyears t*
  • 54. 27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 54timeDeteriorationMachine failure typesstandardFast deteriorationVery fast deteriorationWarning limitAlarm limitInterval time between measurementsOnline / “real time” (protection)Online / multiplexed CMOffline / CM intermittentportable data collectorFailures with very fast deterioration: internal bearing race and rolling elements in bearings, broken shafts, broken fan blades, etcFailures with fast deterioration: external bearing race, wear in gear tooth, etcFailures with standard deterioration: general wear in machines, unbalance and misalignment, etc.Machine failureWhy online? Evolution of failures…
  • 55. 27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 56Justification for online CMS- Some relevant topics are► Increasing trend towards online CMS► Machine is critical to the production process► Detection of rapid evolution of failure► Operating with a known problem► Operating beyond original design► Savings increase profit of plant► Quality Control► Reducing overtime costs► Reducing equipment downtime► Any many more...
  • 56. 27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 57Justification for online CMS Online CMS are used in every industry havingrotating machinery working in its process. Especiallythe so-called critical machinery that has a strongimpact on productivity is monitored with online CMS. Online condition monitoring is performed in variousindustries, such as but not limited to: cement plants,mining plants, power generation companies, papermills, marine industry, wind turbine farms, oil & gassector, etc.Market trends clearly show an increase of machinery health monitoring usingonline CMS.Worldwide more than 1.5 billion USD are spent for Condition Monitoringsolutions.Approximately 50% of investments – roughly 750 millions USD – representacquisition of vibration monitoring equipmentAround 75% of that portion being online CMS, the remaining 25% representportable instruments such as vibration data collectors.Worldwide online CM vs. portable CM-Increasing trend towards online CMS
  • 57. 27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 58Justification for online CMS- Machine is critical to the production process:► Comparing the potential cost of a damaged machine in terms of lost downtime is anexcellent way to justify investments and compute the time frame for ROI.► For example, a process pump is not expensive; however, its impact on production timemay be around $140,000 per hour for a plant.► Therefore, the value of only one unplanned failure could justify a $60,000 online system.► ROI would be achieved by early detection of problems and avoiding only one unplannedfailure. Pumps in an underground mine in Brazil:A series of pumps with SIEMENS motors aremonitored with the VIBRONET® Signalmasteronline CMS.Pumping water out of the mine protects allmachines, ensures an uninterrupted productionand is a must for personnel safety.Even more critical are those pumps directlyinvolved in the mining process – such as pumpsworking with the SAG mills.
  • 58. 27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 59Justification for online CMSMultiplexor VIB 8.306cable VIB 90005VIB 6.122R sensorsOriginal photo of pump in Brazilian mineSubsurface mining – pump monitoring
  • 59. 27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 60Justification for online CMStimeDeteriorationVibration: Warning limitVibration: Alarm limitFast failure evolution= Measurements with route-basedportable data collectorSlow failure evolutionNo detection! Detection possible.- Detection of rapid evolution of failure:► Route-based data collection is sufficient for most machinery, with the average collectioninterval of 4 weeks. But, there are some machines where failure evolution can happenquickly, even within hours. A faulty inner race for example propagates very quickly. Earlydetection is critical and 4-week collection intervals are simply not enough to capture thefault as seen on the graphic.
  • 60. 27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 61Justification for online CMS- Operating beyond original design:► most processes are running near capacity► The trend in industry is to increase output capacity by 10-15%.► This often puts machines just beyond design specifications► Sometimes, this means running into a resonance speed► Condition monitoring identifies how close the unit is to ultimate performance
  • 61. 27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 62Justification for online CMS- Operating with a known problem:► After detection of a problem or fault, the next question is, "How much time do we havebefore we must shut down" or "Can we make it to the next scheduled intervention?"► Trending the fault condition reveals information that is important to estimate the timebefore failure.► Vibration value trends clearly detect variations in the health of the machines as shown inthe graphic.► Additional analysis reveals the root cause of the problem that can be eradicated.timeDeteriorationVibration: Warning limitVibration: Alarm limitMachine can easily runtill next scheduled stopMachine has an increasedfailure probability – stopimmediatelyMACHINE 2MACHINE 1Scheduled maintenance stop
  • 62. 27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 63Justification for online CMS- Quality control:► Another feature of online monitoring is fast feedback on product quality.► For example, on a roll process, chatter between rolls and nips can causevariations in the thickness of the rolled product, producing a "bar" pattern onthe sheet. This fault is commonly known as barring.A propagating failure equals to decreasedquality of final product, not only in the paperindustry.
  • 63. 27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 64Justification for online CMS- External specialists can help► In case required external specialist can access the online CMS► Integrated email server send out notifications in case of alarms► External specialist can be a “second opinion”► Plant can outsource the entire monitoring of critical machines► External specialist can help if plant just lost its specialist until a new one is recruitedVRM KILN MILLSONLINE CMSMACHINESANALYSISMAINTENANCE OPERATORSETHERNETEXTERNALSPECIALISTSCADA HMI
  • 64. 27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 65Do plants go for CM?
  • 65. 27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 67Case studies
  • 66. 27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 68Garadagh Cement (Holcim) - Azerbaijan- Accurate online monitoring*► The online CMS at Garadagh Cement inAzerbaijan performs measurements andsaves them on the OMNITREND® softwareplatform that displays graphics in form ofmeasurement value trends, spectra, timewave form plots, etc.► Trends of measured data from monitoredcompressors and proper alarm settingsenable very quick detection of problematicmachines.► On the right top figure the trend of valuesrecorded with a vibration sensor (picturebottom right) clearly shows an increase of thevibration on an air compressor.► Once an anomaly is detected on a machine,additional measurement data such as spectrais analyzed to find the root cause of theproblem.► After analysis, a diagnosis is done to definethe root cause problem that is theneradicated.Online CMS data visualization (trend values)Vibration sensor mounted on air compressor*Source: ZKG Magazine, Holcim, PRÜFTECHNIK
  • 67. 27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 69Garadagh Cement (Holcim) - Azerbaijan► Garadagh Cement decided to use theVIBRONET® Signalmaster online CMS fromPRÜFTECHNIK as a modern tool to securelyincrease machine reliability to help secureproduction availability, but also to reduce themaintenance costs of monitored machines.► In this case, the maintenance costs for 9compressors and for a period of only fivemonths totaled 51,803 EUR.► The objective was to reduce these costs to 14500 € – a reduction of a factor 3.6! But the realsum required for maintenance costs then onlyreached 2,134 EUR – an overall reduction ofmaintenance costs by a factor of 24.3!► In other words: maintenance costs have beenreduced to only 4 %, a great result.Product uptime ensured with online CMS*Maintenance cost savingsReduced costs for unplanned stops*Source: ZKG Magazine, Holcim, PRÜFTECHNIK
  • 68. 27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 70Oil & Gas applications
  • 69. Monitored machinery- Drilling Machine(Top drive / DDM (Derrick Drilling Machine))► Variable RPM► Low speeds► Variable loads► Many transient events canoccurWithout Drilling Machine NO OIL !27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 71
  • 70. Monitored machinery► Measurement locations27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 72
  • 71. Case Study Drilling MachineCase study I► Instrument used: PRUFTECHNIK – Germany► Software: OMNITREND®► Machine measured: DDM 650 AC (Derrick DrillingMachine)► Measured on site, East Azeri, Azerbaijan  BP.► Operating conditions:● Zero load / Main shaft speed = 269 /Intermediate shaft speed = 1093/ Motor speed = 2300RPM.27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 73
  • 72. Case Study Drilling Machine- Case study I► Vibration analysis● BPFI visible in acceleration time -waveform.380 400 420 440 460 480 500 520 540 560 580 600 620 640 660 680 700 720 740 760 780 800 820 840 860 880 900 920 940t [ms]-1,0-0,8-0,6-0,4-0,20,00,20,40,60,8a [g] SWIVEL 9 SWIVEL RADIAL 1012 VXP Gear time > 600 - 1s 04.11.2006 06:50:38M(436,25)BPFIBPFIHarmonic#20,014a op [g] SWIVEL 9 SWIVEL RADIAL 1011 env_400hz-4000L 04.11.2006 06:50:38FI#2#3#4#5#627/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 74
  • 73. 380 400 420 440 460 480 500 520 540 560 580 600 620 640 660 680 700 720 740 760 780 800 820 840 860 880 900 920 940t [ms]-1,0-0,8-0,6-0,4-0,20,00,20,40,60,8M(436,25BPFIHarmo0 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 320 340 360 380 400f [Hz]0,0000,0010,0020,0030,0040,0050,0060,0070,0080,0090,0100,0110,0120,0130,014a op [g] SWIVEL 9 SWIVEL RADIAL 1011 env_400hz-4000L 04.11.2006 06:50:38(64,11)BPFIBPFIHarmonic#2BPFIHarmonic#3BPFIHarmonic#4BPFIHarmonic#5BPFIHarmonic#6BPFIHarmonic#7BPFIHarmonic#8- Case study I► Vibration analysis● BPFI in envelope FFT, with family of sidebands.Case Study Drilling Machine► This was reported as a level 3 defect. That means you have some time left before youneed to replace the bearing, but needs follow up measurements.► Decision was made to replace the bearing before they started on next drilling job.27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 75
  • 74. Case Study Drilling Machine- Case study I- The Bearing:► Findings:● Heavy / sharp marks on the innerrace. Contamination and water.► Cause:● Most likely vibration damagesduring heavy “yaring”.● Problems with seals(water in the oil)27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 76
  • 75. Case Study Drilling Machine- Vibration Analysis of Drilling Machine2nd Example:► Instrument used: PRUFTECHNIK – Germany► Software: OMNITREND®► Machine measured: DDM 750 AC 1M (Derrick Drilling Machine)► Measured in Workshop – Factory Acceptance Test (MAERSK JACKUP 3)► Operating conditions:● Zero load / Main shaft speed = 216 / Motor speed = 1762RPM.27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 77
  • 76. Case Study Drilling Machine- DDM 750 AC 1M► Needed:■ High resolution time signals■ High resolution spectrummeasurements□ More than 100,000 linesof resolution possiblealso with VIBXPERT®27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 78
  • 77. Case Study Drilling Machine- Vibration Analysis:0 50 100 150 200 250 300 350 400 450 500 550 600 650 700 750 800 850 900 950 1000t [ms]-2,5-2,0-1,5-1,0-0,50,00,51,01,52,02,5a [g] DDM 750 AC 1M, (FAT) 3 RIGHT PINION UPPER 1012 VXP Gear time > 600 - 1s 20.12.2007 13:13:18M(203,48)FTFFTFHarmonic#2FTFHarmonic#3FTFHarmonic#4FTFHarmonic#5FTFHarmonic#6FTFHarmonic#7FTFHarmonic#8FTFHarmonic#90 50 100 150 200 250 300 350 400 450 500 550 600 650 700 750 800 850 900 950 1000 1050 1100 1150 1200 1250 1300 1350 1400f [Hz]0,0000,0050,0100,0150,0200,0250,0300,0350,0400,0450,0500,0550,0600,0650,0700,0750,0800,085a op [g] DDM 750 AC 1M, (FAT) 3 RIGHT PINION UPPER 1008 env_3200hz-6400L 20.12.2007 13:13:25(13,45)FTFFTFHarmonic#2FTFHarmonic#3FTFHarmonic#4FTFHarmonic#5► Vibration analysis ofthe machine duringFAT, detectedimpacts from thecage (train) in thepinion upperbearing.► Visible both inacceleration timewaveform andenvelope FFT.► Bearing wasreplaced and newmeasurementsperformed.► See next slide.27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 79
  • 78. Case Study Drilling Machine► New measurements after bearing was changed:0 50 100 150 200 250 300 350 400 450 500 550 600 650 700 750 800 850 900 950 1000t [ms]-2,5-2,0-1,5-1,0-0,50,00,51,01,52,02,5a [g] DDM 750 AC 1M, (FAT) 3 RIGHT PINION UPPER 1012 VXP Gear time > 600 - 1s 10.01.2008 12:57:25M(203,48)FTFFTFHarmonic#2FTFHarmonic#3FTFHarmonic#4FTFHarmonic#5FTFHarmonic#6FTFHarmonic#7FTFHarmonic#8FTFHarmonic#90 50 100 150 200 250 300 350 400 450 500 550 600 650 700 750 800 850 900 950 1000 1050 1100 1150 1200 1250 1300 1350 1400f [Hz]0,0000,0050,0100,0150,0200,0250,0300,0350,0400,0450,0500,0550,0600,0650,0700,0750,0800,085a op [g] DDM 750 AC 1M, (FAT) 3 RIGHT PINION UPPER 1008 env_3200hz-6400L 10.01.2008 12:57:25M20.12.200710.01.2008Blue color is the lastmeasurement.The impacts from thebearing cagedisappeared!27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 80
  • 79. Case Study Drilling Machine- The bearing:► Cage: Slight wear on the cage and pockets,corrosion and paint.► Inner race: grayish wear pattern andindentations► Conclusion:■ This is not a bearing you would want ina new machine.27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 81
  • 80. Sheaves (fast line / Line sheaves / Chrown block)Monitored machinery27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 82
  • 81.  Fast line sheave lifts up the drillingmachineFast line sheaveDrilling machineVibration analysis of fast line sheave27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 83
  • 82. - Instrument used:► Online Condition Monitoring System VIBRONET® Signalmaster► PRUFTECHNIK – Germany- Software:► OMNITREND®, PRUFTECHNIK- Machine measured:► Fast line Sheave► Measured on site, Eirik Raude, OceanRig.- Operating conditions:► The wire that goes thru this sheave is lifting and lowering the topdrive.► Speed is never constant, and load depends on whats hooked up in the topdrive (can bedifficult for vibration analysis)Vibration analysis of fast line sheave27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 84
  • 83. 20.11.2008 21.11.2008 22.11.2008 23.11.2008 24.11.2008 25.11.2008 26.11.2008 27.11.2008 28.11.2008 29.11.2008 30.11.2008 01.12.2008date0,050,100,150,200,250,300,350,400,450,500,550,600,650,700,750,800,850,900,951,00a [g] Fast line Inner 107 Ov erall ac c el. >1200 50 100 150 200 250 300 350 400 450 500 550 600 650 700 750 800f [Hz]0,00000,00020,00040,00060,00080,00100,00120,00140,00160,00180,00200,0022a op [g] Fast line Inner 1005 Bearing Env elope 22.11.2008 05:52:3823456789101112DM(49,72)BPFO► Bearing trend/noise is slightly developing► BPFO Pattern in envelope, but we can not be sure,because exact speed is not known.Vibration analysis of fast line sheave27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 85
  • 84. ► Decision was made to replace the bearing during a rig move.A similar case in the past caused 7 days downtime.The bearing:► Water / contamination.► Indentations, probablyfrom mounting.• Conclusion:► Water in the lubrication causedthe raised noise. Theindentations on the outer race,caused the BPFO in envelope.Vibration analysis of fast line sheave27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 86
  • 85. Vibration analysis of fast line sheave► This is what happened to asheave bearing which did nothave vibration monitoringequipment installed.-- Unnecessarycosts $$$Another damaged sheave bearing:27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 87
  • 86. Mud Pump► Vibration Analysis of Mud Pump Motor:► Main bearing is monitored online■ Varial conditions (load, speed)27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 88
  • 87. OMNITREND®Software PlatformLAN/EthernetVIBRONET®SignalmasterVIB 3.550 Limiting devices3 ‘string lines‘with triaxial cableVIB 90080General ATEX architectureCoaxial cableVIB 90006 (blue)Mud Pumps – monitored onlineMUX 3machine7+8+9MUX 2machine4+5+6MUX 1machine1+2+3Multiplexor VIB 8.306 EXMUX 6machine16+17+1827/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 89
  • 88. Vibration Analysis of Mud Pump Motor:► Instrument used: online CMS VIBRONET®Signalmaster / PRUFTECHNIK – Germany► Software: OMNITREND®► Machine measured: Mud Pump and Motors► Measured on site => Eirik Raude, Ocean Rig.► Operating conditions:● Motor speed = 619 RPM / 89 Strokes(approx. 50% load)The drilling rig "Eirik Raude" (Ocean Rig) seen fromthe top of the drilling tower.Mud PumpThe drilling rig "Eirik Raude" (from Ocean Rig)27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 90
  • 89. 27.11.2007 25.12.2007 22.01.2008 19.02.2008 18.03.2008 15.04.2008 13.05.2008 10.06.2008 08.07.2008 05.08.2008 02.09.2008 30.09.2008 28.10.2008 25.11.2008date0,00,51,01,52,02,53,03,54,04,55,05,5a [g] Motor A NDE 107 Ov erall ac c el. >1200 50 100 150 200 250 300 350 400 450 500 550 600 650 700 750 800f [Hz]0,000,050,100,150,200,250,300,350,400,450,500,550,600,650,700,750,800,850,90a op [g] Motor A NDE 1005 Bearing Env elope 13.12.2007 00:00:40234 56789DM(37,02)BPFOMud Pump► High bearing noise detected from day one,after system was installed.Vibration analysis of a mud pump motor:► noise came down to normal level afterbearing was replaced.► Detected BPFO in envelope spectra.27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 91
  • 90. Mud Pump► Current is passing through thebearing during operation.The Bearing► The system has detected the sameproblem in 5 mud pump motors outof six (!).► Same problem also detected on drawwork motors.► Next time we detect bearing defectsin these motors they will installbearings with ceramic balls, to solvethe problem.27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 92
  • 91. Draw works, Winches27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 93
  • 92. Draw works, Winches► Online Monitoring■ Variable conditions (load, speed)27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 94
  • 93. Floating Production Units A floating production unit does not have anchors. To stay in position it uses thrusters. For this type of drilling rigs the thrusters has tobe count as “critical machinery“Thrusters arekeeping the rig inthe right positionon the watersurfaceThruster27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 95
  • 94. Thruster MonitoringThrusters are keeping thefloating rig in the right positionon the water surface and count tothe critical machineryThrusters can bemonitoredcontinuously withonline CMS27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 96
  • 95. Thrusters – examples of failures27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 97
  • 96. Oil Rig Jack Bates –Top Drivemonitoring since 2007 (Australia)VIBRONET® Signalmaster online CMS27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 98
  • 97. Oil Rig Jack Bates –Top Drivemonitoring since 2007 (Australia)SENSOR 1:Motor NDE HorizontalBearing# 6326 MC4Variable Speed: 200-1200rpmSENSOR 2:Motor DE HorizontalBearing# 5588 30CVariable Speed: 200-1200rpmSENSOR 3:Gearbox Input Axial (High Speed)Pinion 24 teeth (mounted directly to Motor Shaft)Low Speed Spur Gear 40 teeth/23 teethHigh Speed Spur Gear 34 teeth/32 teethSpur Gear Lower Bearing = McGill BR-1457 Cylindrical RollerBull Gear 114 TeethVariable Speed: 200-1200rpmMULTIPLEXER JUNCTIONBOX INSTALLATIONVIBRONET® Signalmaster online CMS27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 99
  • 98. Reference letter: Ocean Rig27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 100
  • 99. References27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 101
  • 100. Maersk (Denmark)- Online CMS on FPSO► Online condition monitoringin EX environment on a FPSOvessel using VIBRONET®Signalmaster online CMS► Additional sensors will followin the near future► Easily expandable by justadding:1. Additional multiplexers2. Cables3. Sensors● …. without the need ofbuying a new “onlinesystem”27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 102
  • 101. 27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 103Oil & Gas: tank farms In this examplethree (3) VIBRONET®Signalmaster onlineCMS units cover ahigh number ofdecentralizedmachines. The intelligentstring line concepttogether with thefield multiplexermake it an idealsystem for this kindof ATEX application. Several plants canbe monitored andinformation can bestored on a centraldatabase for furtheranalysis anddiagnosis.
  • 102. 27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 104PLCExample: power signal, RPM, temperature,etcExample: alarm signals, CMS status, etc.Oil & Gas: refinery pumpsVIB 8.306 EXfieldmultiplexorsTriaxial cable VIB 90080for string linesLAN/EthernetDistances between last sensor on a string lineand the CMS can be 800m. If the online CMS islocated in the middle of a plant it could covera total distance of1600mstring line 3VIBRONET®SignalmasterVIB 3.550 Limiting devices(one per string line)string line 1 string line 2
  • 103. 27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 105Oil & Gas: fuel pumping stationLAN / EthernetInternet accessOMNITREND®softwareVIB 6.122DEX vibration sensorsVIB 6.610EX temperature sensorsTriaxial cableVIB 90080Online CMS:VIBRONET® SignalmasterVIB 8.306 EX fieldmultiplexorsVIB 3.550 Limiting devices(one per string line)string line 1
  • 104. 27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 106MINING applications
  • 105. 27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 107Triaxial cableVIB 90080Mining: underground mine pumpsVIB 8.306 fieldmultiplexerOriginal photo of pump in Brazilian mineControl RoomExternal expertInternetPLCSignals: Motorcurrent, RPM, etc.Signals: alarm status,CMS status, etc.VIBRONET®Signalmaster string 3string 2string 1
  • 106. 13/03/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 108GUI – BWE drive 1YE 1202MYE 1102YE 1101GE 1207YE 1203YE 1204YE 1106YE 1201SE 1007YE 1105EE 1114140° 0°85°SE 1113180° 180°280°45°135°145°M1leftrightConical gearboxsidePlanetarygearbox sideVibrationGear meshBearingsMachine dataParametersoperationOnline trendsAlarm System status Trend Diagnostic Back StartVIBRONET - Online Condition MonitoringGearbox – drive 1Connection statusYE - AccelerationGE - DisplacementSE - RPMEE - Load
  • 107. 13/03/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 109GUI machine level – BWE 546 – SRs 2000-LubCos_ÖlzustandsüberwachungAP-BA_Beschleunigungssensor-BT_Temperatursensor-BN_Drehzahlsensor-BM_DMS_Momentenmessung-BP_DrucksensorMMomentanwerteMaschinendatenBA1101BA1102BA1103BA1104BT1201BT1202BT1203BT1204BM1105Schwingung Kegelritzelwelle oben radialSchwingung Kegelritzelwelle oben axialSchwingung Kegelritzelwelle unten radialSchwingung Kegelritzelwelle unten axialTemperatur Kegelritzelwelle oben Lager 1Temperatur Kegelritzelwelle unten Lager 2Temperatur Kegelritzelwelle unten Lager 1BT1205 AußentemperaturAbtriebsmomentBP1106BP1107BT1206Öldruck vor FilterÖldruck nach FilterÖlsumpftemperaturBN1301 EingangsdrehzahlLubCos ÖlzustandsüberwachungTemperatur Kegelritzelwelle oben Lager 2Warnung Signalanalyse Zurück StartseiteAlarm SystemNormalWarningAlarmOpen CircuitDisabledBE1303 Kupplungsschlupf (Temperaturüberschreit.)VIBROWEB XP - Online Condition MonitoringSchaufelradbagger 546 – SRs 2000 TAKRAF GmbHlinksrechtsKegelradseitePlanetenseiteAntrieb 1(oben)MBelchatow / PolenAntrieb 2(unten)APPÖlfilter
  • 108. 13/03/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 110Belt conveyor system – typical defecttypesUnbalance Misalignment WearWear Gear meshproblemBroken TeethUnbalanceCracks DeformationWearCracksBearing Defect WearElectricalUnbalance ElectricalMotorGear BoxDrive BeltPulley
  • 109. PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 111References: Brazil - Jaguar Mining Inc* With variable conditions: load and RPMBALL MILLS: 24 hours a day 7 sensors per mill 2,5MW Siemens motorVibration sensorPRUFTECHNIK VIBROWEB XP27/04/2013
  • 110. References: Brazil - Jaguar Mining IncPRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 112Problem: The shaft was breaking often, causing low machine availability and high maintenance costs Maintenance was performed in monthly basis (preventive), but the faults didn’t follow a pattern No information regarding the vibration of the machineAfter the implementation of an Online Monitoring System: Maintenance labours are performed based on the machines vibrations The shaft hasn’t broken since, hence raising machine availability Positive feedback from the customerMonitoring withOnline VIEW27/04/2013
  • 111. Some mining referencesPRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 113Mine Device productMafube VIBXPERT® II CoalPhola VIBXPERT® II CoalKriel Vibnode CoalGreenside VIBXPERT® II,VIBXPERT® EXCoalSishen VIBSCANNER® IronAngloAmerican Coal MinesSouth Africa Drummond Company, Inc.Colombia / VIBROTIP® + VIBCODE® Evolution MiningAustraliaMine Device ApplicationCracow 1 VIBROWEB®, 2WEARSCANNER®Ball millsPajingo 1 VIBROWEB®, 2WEARSCANNER®Ball mills27/04/2013
  • 112. Some mining referencesPRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 114 XstrataAustraliaMine Device ApplicationAbbot Point 2 VIBNODE® Stack reclaimerMount Isa 1 VIBROWEB®,1 VIBXPERT® IIUnderground jaw crusherGeorge Fisher 1 VIBROWEB®,1 VIBXPERT® IIVertical cone crushersGeorge Fisher 1 VIBROWEB®,1 VIBXPERT® IIVent fansZinc VIBNODE® Mobile crane analysis oncrab wheelsCopper 2 VIBROWEB®XP, 1 VIBNODE(R),1 VIBXPERT®Anode crane, fansOaky No. 01 12 VIBROWEB®, 2 VIBXPERT®II Conveyor beltsOkay North 5 VIBGUARD®, 2 VIBROWEB®XP Longwall monitoring BHPAustralia / 3 VIBROWEB®XP + 1 VIBXPERT® / Fans27/04/2013
  • 113. Mining trucks under controlPRUFTECHNIK Middle East FZE (Dubai) - Robert Schmaus 115Stand Test with VIBXPERT®II Multiplexer support Measure during routine visits to the shop Motor is set to run always at the same constantspeed MUX and sensors can be installed permanentlyon truck13/03/2013
  • 114. PRUFTECHNIK Middle East FZE (Dubai) - Robert Schmaus 116SAG Mill Feed Conveyor: electric motor + FALK gearboxExample of Conveyor Gearbox monitoringLAN / EthernetMotor:Power: 300kW / 402 HPSpeed: 1195 RPMGearbox:Output shaft: 66 RPMOnline CMS13/03/2013
  • 115. PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 117References: special mining equipment* VATTENFALL Europe Mining – Welzow Süd MineGermany / online monitoring of Bucket WheelExcavators SRs 6300 & conveyor systems, since1997 Maritza MineBulgaria / online monitoring of Bucket WheelExcavator SRs 4000+VR & conveyor systems The fourth largest bucket wheel excavator in theworld! Elektrownia Bełchatów Power PlantPoland / online monitoring of Bucket WheelExcavators SRs 2000 & conveyor systems QNI – Quensland NickelAustralia / port crane system online monitoring atYabulu refibery* With variable conditions: load and RPM27/04/2013
  • 116. 27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 118RAW MILL 1 [8]KILNFAN[6] KILN DRIVE[8]COOLING FANBOOSTER [5] KILN FAN [5]COAL MILL [9]CEMENT MILL 2 [7]CEMENT MILL 3 [7]DRY FAN [6]SEPARATOR [7]RAW MILL SEPARATOR 1 [8]RAW MILL SEPARATOR 2 [8]SEPARATOR [7]CMSCLINKER CRUSHERPOLYTRACK [5]Cement: plant monitoringRAW MILL 2 [8]SEPARATOR [7]
  • 117. 1 2 34 5678 910 1112Vertical Roller Mills (VRM) –measurement locations & parameters (examples)Typical defects Drive motor: imbalance, misalignment,wearelectrical problems, bearing condition Gear box: gear mesh of pinion andplanetary stage; bearing condition atdrive shaft; oil supplyMILLINGSEPARATIONMeasurement location examples1-3 = Motor, bearing condition + vibration RMS4-11 = Gearbox, input, bevel gear, planetarystage12 = Torque measurement Additionally: motor currentParameters for gearbox:- Spectra, envelope spectra and vibrationacceleration- Perform band analysisGrinding table: Temperature of friction bearingOptional: mill feed, power, loads, etcOil supply:- Temperature- PressureFLSATOXVerticalRollerMillAccelerometer sensorsProximity sensorsTorque measurements27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 119
  • 118. Gearbox input shaftExample of vibration sensor mountedon gearbox input shaft27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 120
  • 119. Online visualization with OMNITREND® OnlineView27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 121
  • 120. OPTION: Torque measurement27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 122
  • 121. Installation of Torque measurement point27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 123
  • 122. 27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 124Reference Letters
  • 123. Reference letter: Ocean Rig29/04/2012PRUFTECHNIK Middle East FZE (Dubai) - Robert Schmaus 125
  • 124. 29/04/2012PRUFTECHNIK Middle East FZE (Dubai) - Robert Schmaus 126Oil & Gas: sample reference letter of BP
  • 125. 27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 127Summary- Condition Monitoring is very important for a plant► Increases plant’s reliability► Detects machines with problems and helps finding source of failures► Reduces the number of unnecessary machine stops► Knowing the failure, repairs can be planned at the most effective time, partscan be ordered and labor can be organized well in advance► Ensures machine uptime, decreases loss of production► Decreases costs for maintenance, costs for stock, reduces energyconsumption of machines... and much more...► Prevents from safety and environmental issues► Helps to increase PROFIT of plants► And...
  • 126. 27/04/2013 128PRUFTECHNIK Middle East FZE- www.pruftechnik-me.com- www.pruftechnik.aePRUFTECHNIK Middle East FZE (Dubai) – Robert SchmausWe are close to you. Because we care.PRUFTECHNIK Middle East / Dubai – UAE / Phone: +971 4 214 6386