Vibration Analysis, Emerson Makes it Easy for You
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One of the most powerful tools to deploy reliability centered maintenance are portable vibration measurements. With the new portable vibration analyser of Emerson, portable vibration analysis is now made easier than ever before. By the following slidedeck you'll get an introduction to the basics of vibration analysis and the capabilities of the CSI2140
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Vibration Analysis, Emerson Makes it Easy for You
- 1. Introduction to PortableIntroduction to Portable Vibration AnalysisVibration Analysis Dieter Charle BDM Portable Reliability Solutions | Europe 5/11/2015
- 2. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 2 US $24.5 Billion in Sales Emerson At-A-Glance 2015 Manufacturing and/or sales presence in more than 150 countries 220 manufacturing locations around the world No. 121 on 2014 FORTUNE 500 list of America’s largest corporations Founded in 1890 NYSE: EMR Headquarters in St. Louis, Missouri USA Diversified global manufacturer and technology provider Approximately 115,000 employees worldwide
- 3. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 3 Emerson Invests in New Technology Development to Meet Customer Needs $805 million … Emerson’s investment in Engineering & Development during 2015 1,900+ … patents awarded in 2015 to Emerson businesses
- 4. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 4 US & Canada Sales $11.2 Billion Employees 32,000 Locations 75 Latin America Sales $1.5 Billion Employees 18,000 Locations 30 Western Europe Sales $3.8 Billion Employees 16,000 Locations 45 Middle East & Africa Sales $1.5 Billion Employees 1,000 Locations 5 Eastern Europe & Russia Sales $1.0 Billion Employees 9,000 Locations 15 Asia Sales $5.5 Billion Employees 39,000 Locations 50 Note: Locations include manufacturing locations only. Our Business Objective To design, engineer, manufacture, sell and support our products and solutions in every region of the world Emerson Global Presence 2015
- 5. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 5 Our Industry Challenges • Eliminate unplanned production shutdowns – Minimize exposure – safer work environment – Improved uptime • Prioritize and plan maintenance actions • Extend time between planned shutdowns • Reduce inventory costs • Increase availability and performance of assets • Reduce preventive maintenance MotorsMotors PumpsPumps TurbinesTurbinesGearboxesGearboxes
- 6. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 6 Emerson’s Reliability Solutions
- 7. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 7 Portable Vibration Analysis – Industry Requirements • Easy Routine Data Collection • Get Faster Diagnoses - Coherence case history - Complex, hard to access machinery • Advanced Diagnostics - Detect misalignment during operation - Live monitoring sleeve bearings - Commissioning smaller turbines - Structural Analysis StandardAdvanced
- 8. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 8 Vibration Analysis "Of all the parameters that can be measured non-intrusively in industry today, the one containing the most information is the vibration signature.“ - Art Crawford, Consultant / Author - In one study, nearly two thirds of the entire benefit from Machinery Health Monitoring came from Vibration Analysis - John E. Amos Power Station - 65% Vibration Analysis
- 9. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 9 Vibration Analysis – Basic Principle • Mechanical faults generate unique vibration – Geometry of the machine • diameter of the shaft • number of bearing elements • Type of bearing elements – Turning speed (e.g. RPM) HighLow Mechanical Defects detected with vibration analysis Belt drive faults Imbalance Misalignment Bent shaft Shaft Rub Looseness Machine resonance Bearing Defects including: •cage defect •outer race defect •inner race defect •rolling element defect Gear defects Electrical faults Cavitation Lubrication
- 10. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 10 Vibration from Mechanical Faults
- 11. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 11 Vibration from Mechanical Faults Imbalance 1 x RPM
- 12. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 12 Vibration from Mechanical Faults Blade Pass 4 x RPM
- 13. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 13 Vibration from Mechanical Faults Gear Mesh 17 x RPM
- 14. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 14 Vibration from Mechanical Faults Blade Pass 4 x RPM Gear Mesh 17 x RPM + Imbalance 1 x RPM +
- 15. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 15 Frequency Amplitude How the Vibration Spectrum is Created Time Amplitude Time Amplitude
- 16. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 16 Roller Bearing Faults Four different bearing frequencies Ball Pass Frequency Inner Race (BPFI) Ball Pass Frequency Outer Race (BPFO) Ball Spin Frequency (BSF) Fundamental Train Frequency (FTF)
- 17. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 17 How Bearing Faults Generate Vibration
- 18. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 18 One tool to WIN all challenges Industry Requirements Modular Multi-Technology Platform Easy Routine Data Collection • Vibration Routes • PeakVue Analysis Get Data Faster - Coherence case history - Complex, hard to access machinery • 4-channel Analysis • In-field Alarming • Fault Frequencies • Parameter Trending Advanced Diagnostics - Detect misalignment during operation - Live monitoring sleeve bearings - Commissioning smaller turbines - Structural Analysis • Cross Channel Analysis • Vibration Analysis/Troubleshooting • AC Motor Rotor Bar Analysis • 4-Plane Balancing • Dual Orbit Plotting • Transient Analysis • ODS/Modal Analysis StandardAdvanced
- 19. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 19 Lower Cost = Earlier Warning = PeakVue PeakVue is easy! • One single value to interpret • Earlier warning than any other technology • Indication of fault and severity Progression of a Typical Machine Problem PeakVue Alert EquipmentHealth Time EquipmentEquipment FailureFailure PeakVue alert Oil analysis Temperature monitoring Overall Vibration Audible noise Hot to touch Spectrum Analysis Vibration analysis Consequence Time Easy
- 20. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 20 Vibration in/s mm/s Minimal Warning 0.15 / 3.7 Good 0.15 / 3.7 Good 0.15 / 3.8 Good 0.16 / 4.0 Good? 0.18 / 4.5 OK? 0.30 / 7.5 Failure occurs!!! Onsetof Fault Bearing Failure FAULTFAULT ALERTALERT FAULTFAULT ALERTALERT No Warning! Time To Plan PeakVue g’s Early Warning with Severity 0 Good 10 Alert – Notify maintenance 20 Problem getting serious. 30 Near end of life 40 Take action! Bearing failure imminent 50 Failure occurs!!! 0 10 20 30 50 40 0.0 0.1 0.2 0.3 0.4 0.5 PeakVue(g’s)Vibration 0.0 2.5 5.0 7.5 12.5 9.0 After Repair Overall Vibration vs. PeakVue Easy
- 21. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 21 PeakVue is Easy Two Simple Rules: PeakVue (g’s) Interpretation 0 Good machine 10 Some Issue 20 Serious problem 40 Action Point Reliability 101 for Operators 2. Rule of 10’s • 10 – something’s happening • 20 – something serious happening • 40 – time to take action 1. Zero Principle PeakVue on a good machine is at or close to zero Easy
- 22. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 22 The magic behind Vibration Analysis Enveloping registers (Demodulation) Raw measurement data - Waveform Signal after rectifying Signal after band pass filter Easy
- 23. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 23 The magic behind Vibration AnalysisPeakVuePeakVue Peak Impact Detection registers Raw measurement data - Waveform Signal after rectifying Signal after band pass filter Easy PeakVue: -Keep High Frequency Sample -No Low Pass Filter
- 24. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 24 The magic behind PeakVue Peak Impact Detection registersEnveloping registers (Demodulation) 1000 Hz 200Hz 8 g’s 108g’s 50Hz >1 g 108g’s 28 g’s 108g’s Demodulation Amplitude PeakVue Amplitude Bandwidth G’s Error G’s Error 1000 Hz 28 74% 108 0% 200 Hz 8 92% 108 0% 50 Hz 0.5 99% 108 0% Easy
- 25. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 25 PeakVue Case Study – Outer Race Defect 359 RPM Peak Impact Detection registersEnveloping registers (Demodulation)
- 26. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 26 Five Inputs / Eight Live Plots Five Inputs: Channel 1 Channel 2 Channel 3 Channel 4 Plus Tachometer 8 live plots
- 27. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 27 Patented Emerson Triax = Easy and Fast! Fast
- 28. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 28 Where to Use Triax or 4 Channels? • Everywhere in Route Mode – Easier – Faster Example: Paper Plants (dryer section) • Turbines Start-up (need to see phase info at both planes, so 4 Channels+Phase) • All Advanced Applications Where Cross Channel Data is Needed Fast Advanced Advanced
- 29. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 29 SpeedVue = Easy and Fast Fast Measure rotating speed without reflecting tape? Yes, it is possible! Laser speed sensor Measure surface shape of shaft Calculates the rotation speed
- 30. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 30 In Field Analysis • Colored parameter alarms, provide immediate indication of Machinery Health • See what parameter is in alarm and its severity immediately at the point of data collection • Fault Frequencies help identify the source of the vibration • Fault Frequencies help identify the source of the vibration Parameter Alarms Fast Fault Freq A A A A B B B B Fault Frequencies Fault Freq A A A A B B B B M1H - RPM May 2007 – July 2007 Ampl: 1713.47 June 12 2007 Next Trend Prev Trend Trend
- 31. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 31 Analysis Tools in the Field • Analysis Experts are preconfigured so even a novice can use them. • Allows troubleshooting tests to be performed while next to the machine without making a return trip Advanced
- 32. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 32 Four Voltage Channels + Tachometer Dual Orbits!Dual Orbits! Advanced
- 33. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 33 Orbit Plots: Monitor 2 Sleeve Bearings • True Orbit Plot – Measure displacement – 2x dual eddy current sensors @ 90° apart Advanced
- 34. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 34 Four Voltage Channels + Tachometer andand Four AccelerometerFour Accelerometer Channels + TachometerChannels + Tachometer Advanced
- 35. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 35 Transient analysis Analyze the detailed spectrum and waveform by sliding of interest bar Advanced
- 36. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 36 Laser Shaft Alignment Use my analyzer tool for simple & advanced Shaft Alignment? Yes, it is possible! Via Bleutooth Communication Basic and Advanced Modes - Add compensation factors - Full or Partial Sweep Advanced
- 37. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 37 Single and Multi Plane Balancing Advanced Use my analyzer tool for simple & advanced balancing jobs ? Yes, it is possible! Laser position sensor + tape Acquire reference run data Add or remove trail weights (plane 1, 2, etc) View balance correction Collect trim run data for corrected condition
- 38. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 38 Cross-Channel Phase Check for Misalignment – Measure across a coupling – Check phase at running speed Advanced
- 39. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 39 Structural Analysis Options Advanced • Operating Deflection Shape – Performed while machine in operation – Single frequency (typically running speed) measurement – Can be performed with any CSI machinery analyzer – Four channel is recommended – Measures actual amplitude of deflection – Shows how machine deflects in normal operation • Modal Analysis – Requires machine to be shut down – Analysis across all frequencies – Requires dual or four channel CSI 2140 for measurements – With 4 channels: 1 channel is reference + triax – Determines ratio of response to input, no absolute amplitudes – Detailed model of machine stiffness, resonances, etc.
- 40. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 40 ODS on Piping • Triax sensor + ODS offers more locations to collect data • Due to Triax no more Software interpolation required Advanced
- 41. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 41 Some other ODS-examples Advanced
- 42. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 42 Modal Analysis or Coherence Case History • Verify if vibration is related across points • Reoccurring failure on paper machine – Unusual vibration present – Matched turning speed of pump below • Coherence measurement – proved that vibration was related • Fixing pump operation – solved paper machine problems Advanced
- 43. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 43 Resonance • Natural frequencies are directional • So, you need to measure in Horizontal, Vertical and Axial direction. • With CSI 2140, all directions can be measured simultaneously • For hammer impact tests, your hammer is channel 4 Advanced MOTOR
- 44. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 44 Impact Test Application • Structural Analysis – Identify resonances – Measure stiffness – Determine system response – Modal analysis • Use One Hammer and Three Accelerometers • Use One Hammer and One Triax Sensor MOTOR Advanced
- 45. Ergonomics andErgonomics and FeaturesFeatures CSI2140 The Portable Vibration Analyzer of the future
- 46. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 46 Screen & Keyboard Automatic Backlight Backlit Keyboard Huge LCD Display Touchscreen – glove compatible!
- 47. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 47 00998877665544332211009988776655443322110099 Thin Profile 66554433 mm
- 48. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 48 Built-in Stand
- 49. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 49 Comfortable New Strap
- 50. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 50 Communications Ethernet Port Wi-Fi to AMS Machinery Manager Bluetooth to accessories Ethernet USB 2.0 Wi-Fi Load Routes using USB Memory Stick
- 51. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 51 Remove Wires to Increase Safety >>>>>>>>>>>>>> >>>>>>>>>>>>>> Customer Quote: “The fact is, today none of my vibration techs would do a route without headphones.” Customer Quote: “The fact is, today none of my vibration techs would do a route without headphones.”
- 52. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 52 E-mail Route/Data Files • Upload data to local PC with FREE software • E-mail, FTP, or copy across network from remote location to database or SME for archive and analysis
- 53. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 53 Li-ION Battery - Full 10 Hour Shift External Charger 8 Hr 24 Hr Car Charger
- 54. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 54 Memory 1GB Internal External 32GB SD card
- 55. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 55 New Accessories • CSI 2140 4-Channel Input Adapter (Accel & Volts) • Splitter Cables for 4-Channel • Car Charger • Bluetooth Wireless Headphones • External Battery Charger
- 56. Questions?Questions? Dieter Charle BDM Portable Reliability Solutions | Europe Dieter.charle@emerson.com +32 493 229 991
Editor's Notes
- Emailed Rich.
- Simultaneous 4-channel measurements on the CSI 2140 can be used almost anywhere. From speeding up routing data collection with a triaxial accelerometer to more advanced troubleshooting tests like transient, cross channel, dual orbits, ODS/Modal, etc.
- L1 - weakening of metal, no pits L2 - Small pitting/holes L3 - clear indication L4 - going to fail within days/weeks L5 - machine failing
- Four accelerometer/voltage channels plus phase input really makes it a five channel instrument. Some other brands of vibration analyzers can only do 3 channels plus phase or four channels without phase. The large 7.5” diagonal, full VGA resolution, color screen allows for easy and useful display of up to 8 live plots so the user can see the data as it is being collected from each of the four channels.
- Using the 4-channel input adapter the user can monitor sleeve bearing machines with the 4-channel volts measurement plus phase for dual orbit plots to monitor shaft movements
- In addition to monitoring rolling element bearings, the 4-channel CSI 2140 is also excellent for monitoring sleeve bearings to get dual orbits from the displacement probe signals through the protection system rack.
- Turn the 4-channel input adapter over and the user can rolling element bearing machines with the 4-channel accelerometer measurements plus phase for cross channel phase, transient, ODS Modal, and much more.
- An area of
- An easy test for misalignment is to measure cross channel phase across the coupling of a machine. If the cross channel phase across the machine is 180 degrees plus or minus 30 degrees then misalignment is a probable fault condition.
- Coherence can be used to see if the vibration that is being measured is actually coming from the machine being measured or from another source like a nearby neighbor machine.
- The screen is 13X brighter than the CSI 2130 screen and can easily be seen outdoors in bright sunlight. The touchscreen works with gloves. The keypad is backlit for easy visibility in dark environments.
- The CSI 2140 is much thinner than the CSI 2130 and comfortably fits in the hand for all day route data collection.
- The built-in stand is useful for standing the CSI 2140 upright on the desk or out in plant when collecting longer transient, balance, or slow speed data. The stand also works with the 4-channel adapter attached.
- A wide, stretchable, non-slip neoprene strap for comfortable all day data collection. The strap easily attaches or detaches to the CSI 2140 with the push of a button.
- USB 2.0 is twice as fast as the CSI 2130’s USB 1.0. Wired Ethernet or wireless Ethernet (Wi-Fi) can be used to directly communicate with the AMS Machinery Manager database across a corporate network without the need for AMS Machinery Manager on the local PC. Users can listen to the vibration at the same time as watching the vibration plots with wireless Bluetooth enabled headphones to provide another dimension to analyzing machinery health.
- No doubt — headphones add benefits to route-based analysis. But headphone cords that attach to the handheld analyzer can become a nuisance. But even more serious, cords present a safety risk by catching on machinery and endangering both the technician and the process. Listen to the vibration signal for impacting sounds while you are watching the vibration plots during collection Listening to the vibration while you are collecting the data and watching the vibration plots on the analyzer can allow the user to associate the sound with the data plots further add further clues to their investigation of machinery health.
- Li-ION battery will last 10+ hours collecting 4 simultaneous channels and full backlight continuously. The battery can be easily removed and swapped with a spare fully charged battery via the external battery charger. A car charger accessory is available to charge the CSI 2140 battery while driving to your location.
- 1 GB of internal memory and up to 32GB SD cards mean virtually unlimited memory and no more return trips to the office to unload and reload the unit during data collection.