Protective Maintenance Fans Cement


Published on

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

Published in: Education, Business, Technology
  • Be the first to comment

No Downloads
Total views
On SlideShare
From Embeds
Number of Embeds
Embeds 0
No embeds

No notes for slide

Protective Maintenance Fans Cement

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