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online_failure detection

  1. 1. Early detection of machinery failures using onlineCondition Monitoring Systems (CMS)PRUFTECHNIK Middle East FZE (Dubai) / Robert Schmaus / 28-04-2013
  2. 2. 27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 2
  3. 3. 22/03/2012PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 3
  4. 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. 5. COMPANY PROFILEPRUFTECHNIK27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 5
  6. 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. 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. 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. 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. 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. 11. 04/02/2013PRUFTECHNIK Middle East FZE (Dubai) - Robert Schmaus 11Some of our target marketsOil & Gas Off Shore PowerWindMarineChemical Paper / FilmsSugarTextileCementMiningSteelWaterServicesAutomotive
  12. 12. Some worldwide references27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 12FEWA - United Arab Emirates
  13. 13. 27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 13Introduction
  14. 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. 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. 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. 17. 27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 17A typical plant
  18. 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. 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. 20. 27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 20Machine healthmonitoring
  21. 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. 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. 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. 24. 27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 24Level 1 and Level 2strategy
  25. 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. 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. 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. 28. 27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 28The rightmeasurement tools
  29. 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. 30. 27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 30Offline measurements
  31. 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. 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. 33. - Multiplexer support(Automatic Switchbox)…- just a step beforeimplementation of online CMS27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 33
  34. 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. 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. 36. 27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 36Online ConditionMonitoring systems(CMS)
  37. 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. 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. 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. 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. 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. 42. 3-D Spectra, waterfall diagram27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 42
  43. 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. 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. 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. 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. 47. Examples of bonded adaptersICP typeCLD type CLD type27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 47
  48. 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. 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. 50. 27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 50When do I need onlineCMS?
  51. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 64. 27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 65Do plants go for CM?
  65. 65. 27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 67Case studies
  66. 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. 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. 68. 27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 70Oil & Gas applications
  69. 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. 70. Monitored machinery► Measurement locations27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 72
  71. 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. 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. 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. 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. 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. 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. 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. 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. 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. 80. Sheaves (fast line / Line sheaves / Chrown block)Monitored machinery27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 82
  81. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 91. Draw works, Winches27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 93
  92. 92. Draw works, Winches► Online Monitoring■ Variable conditions (load, speed)27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 94
  93. 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. 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. 95. Thrusters – examples of failures27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 97
  96. 96. Oil Rig Jack Bates –Top Drivemonitoring since 2007 (Australia)VIBRONET® Signalmaster online CMS27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 98
  97. 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. 98. Reference letter: Ocean Rig27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 100
  99. 99. References27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 101
  100. 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. 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. 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. 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. 104. 27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 106MINING applications
  105. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 118. Gearbox input shaftExample of vibration sensor mountedon gearbox input shaft27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 120
  119. 119. Online visualization with OMNITREND® OnlineView27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 121
  120. 120. OPTION: Torque measurement27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 122
  121. 121. Installation of Torque measurement point27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 123
  122. 122. 27/04/2013PRUFTECHNIK Middle East FZE (Dubai) – Robert Schmaus 124Reference Letters
  123. 123. Reference letter: Ocean Rig29/04/2012PRUFTECHNIK Middle East FZE (Dubai) - Robert Schmaus 125
  124. 124. 29/04/2012PRUFTECHNIK Middle East FZE (Dubai) - Robert Schmaus 126Oil & Gas: sample reference letter of BP
  125. 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. 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

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