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Introducing 810 Vibration Tester: Get Answers Now
Introducing 810 Vibration Tester: Get Answers Now
BeforeWeBegin
Ask questions at any time! Please turn your cell phone to vibrate. If you must take a call, please feel free but we ask that you take it outside the seminar room.
Agenda
Maintenance practices What is mechanical vibration? What are the benefits of vibration testing? How a vibration meter works Vibration basics Introduction to the Fluke 810 Vibration Tester Vibration Testing in 3 Easy Steps Setting up the machine Taking a proper measurement Interpreting the diagnosis Viewer PC software How to start testing vibration in your facility
MaintenancePractices
ReactiveMaintenance:Oftencalledruntofailure. Norepairormaintenanceactions aretakenonmachineryuntilthedesignedlifespanisreachedorothervariables causethemachinerytofail. Upside:
Lowerupfrontmaintenancecosts Lowermaintenancestaffcosts Unplanned,sometimescatastrophic,downtimeandovertimehours Secondarydamagetomachinesimpactedbythefailedmachine Potentiallyhighercapitalcostsasentirecomponentsmayneedtobereplaced Machinescontrolmaintenancedepartment
Downside:
Downside:
Faultfreemachinesmaintainedunnecessarily couldleadtoincidentalproblemswith components Overhaulreducesreliabilityofthemachine(seethebathtubcurve) MorelaborintensivethanReactiveMaintenance
MaintenancePractices
PredictiveMaintenance(Proactive ConditionBased):Useofdifferenttesting (vibration,thermography,oilanalysis,ultrasoundarethemostcommon)to understandmachineconditionandpreventfailure Upside
Allowspreemptiveactiontoincreaseequipmentlife Increasedequipmentlife Reducedequipmentorprocessfailure Reducedrepairpartsandlaborcosts Increasedsafety Reducedlikelihoodofcatastrophicfailures Increasedinvestmentindiagnostic/testequipment Increasedinvestmentintrainingandstaff Costbenefitsnotreadilyseenbymanagement Mayrequiretopdownculturalchangeinmaintenanceapproach
Downside
EarlyIndicatorsofMachineHealth
Intheworldofmechanicalmaintenance,vibrationremains oneoftheearliestindicatorsofamachineshealth.
Point where failure starts to occur P P = Potential Failure Wear Debris in Oil P-F Interval 1-6 mos P 1 P 2 Quantitative PM P-F Interval 5-8 wks P 4 P 5 P6
P 3
F
The P-F Curve, Adapted from John Moubrays book Reliability Centered Maintenance II
F = Failure
CurrentSolutionsNotforEveryone
Currentvibrationanalysistoolsrequireacommitment Upfrontinvestment Fulltimeresourcestolearnandperformvibration analysis Manyfacilitiescannotmakethenecessaryinvestment, yetstruggledailywithmechanicalbreakdowns. Theonlyoptionsavailabletothesefacilitieshave included: Changingpartsregularlybeforetheywearout Outsourcingvibrationanalysistoconsultants Usingsubjectivetechniques Simplyfirefighting orrunningtofailure Maintenanceteamsneedhelpgettinganswerstotheir mechanicalproblemsNOW.
AVibrationProgramPaysforItself
CostofDowntime/Repair
1.Netincomeperhourofoutputforproductionlineorothercriticalprocess 2.Calculatetheaveragedowntime(duetomechanicalfailures)foreachequipment failureandnumberofeventsperyear. 3.Multiplytheresultsofstep1bybothvaluesinstep2. 4.Estimatelabor(overtime)andequipmentpartscostperdowntimeincident 5.Addstep3andstep4.Thisistheannualcostinlostrevenueplusrepaircosts
Cost(RTF)
$20,000/hr(critical&noncriticalmachinefailures) 8hrsdown,5motors,1x/yr ($20,000*8)*5=$800,000 $30/hr*8hrs*2techs=$480+$5000/motor=$5480 $805,480(duetocritical/noncriticalfailures)
CostofProgramImplementation
1.Averagecostofcurrenttestequipment(hardwareandsoftware) 2.Averagecostofdedicated,experiencedvibrationtechnician(FTE)(Assume1man hour/motor/month) 3.Averageupfrontequipmenttrainingcosts+maintenancetraining 4.Addsteps1throughstep3.Thisisthetotalfirstyearcostofprogramstartup
Cost
$30,000 1hr/mo/motor*150motors*12mos/yr*$35/manhr= $63000 $6000 $102,000
VibrationTestingPayback
1.Assume50%ofunplanneddowntimeandrepaircostssavings 2.ReturnonInvestment&Paybackofvibrationtestingprogram(totalcostperyear/ totalsavingsperyear)
Cost
$805,480*50%=$402,740 $102,000/$402,740=0.25yrsor3mos
Basicvibrationtestingprogramspayforthemselvesbutcurrentsolutionsaredesigned forexperiencedvibrationanalystswithinapredictivemaintenancecontext Upfrontcosts (hardware,software,training, headcount)canstillbehigh 2010 Fluke Corporation Introducing 810 Vibration Tester 8
BenefitsofVibrationTesting
Vibration provides the earliest indicator of machine condition Vibration addresses all the moving parts of rotating equipment and can identify root cause Saves time by addressing problems earlier Saves money by reducing spare parts inventories
WhatisMechanicalVibration?
MechanicsofVibrationTesting
Transducerpicksup vibrationsignalsfrom bearinglocationsand transmitsthemtoa datacollectiondevice
Exampleofatimewaveform
MakingVibrationDataEasiertoInterpretKindOf
Thewaveformcontainsalltheinformationaboutthe vibrationofthemachineatthepointwhereitwas measured Buttheindividualpatternsofvibrationcausedbydifferent eventsinthemachinearealloverlappedandjumbled together.
Exampleofatimewaveform
FFT
Exampleofavibrationspectrum
CommonMachineFaults&SpectrumAnalysis
Everymachineryfaultproducesaunique typeofvibrationsignal. Signalsdisplayedinthevibration spectrumoftenformcharacteristic patterns. Patternrecognitionisakeypartof vibrationanalysisbutsignificanttraining andexperiencearenecessarytoreadthe patterns. Inthisseminarwewillanalyze4different typeoffailures: Imbalance Misalignment Looseness BearingFailures
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WhatisImbalance?
Imbalanceisaconditionofarotatingpartwherethe centerofmassdoesnotlieontheaxisofrotation.In otherwords,thereisaheavyspot somewhereon therotor.
Thelargepeakof124VdBat1Xrunningspeedis causedbytheimbalance.
140 130 120 110 100 90 80 70 60 0 1 2 3 4 5 6 VdB
Theotherpeaksarecausedbydifferent phenomenainthemachine
ORDERS
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SourcesofImbalance
Variousmachineconditionscanresultinimbalance: Dirtaccumulationormissingbalanceweights Lackofhomogeneityinmaterials,especiallyincastings(e.g.poroussections, blowholes) Differenceindimensionofmatingparts(e.g.shaft,bore) Rollerdeflection(e.g.papermillrolls)ormachiningerrors Unevenmassdistributioninelectricalwindings Unevencorrosion,eccentricrotororerosionofrotors
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WhatisMisalignment?
Inmachines,perfectalignmentoccurswhenthecenterlineoftwo coupledshafts coincide.Whentheydonotcoincide,misalignmentexists. Threetypesofmisalignmentarepossible: Angular thecenterlineofthetwoshaftsintersectbutarenotparallel.
AngularMisalignment
Parallel thecenterlineofthetwoshaftsareparallelbutnotconcentric.
ParallelMisalignment
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SourcesofMisalignment
Misalignmentcanbecausedbyseveralsources,including: Poorassemblyorshiftingafterassembly Distortionduetopipestrain Distortionduetotorquecombinedwithflexiblesupport Temperatureinducedgrowthofthemachinestructure Poorlymachinedcoupling Inadequatecouplinglubrication
Misalignmentwillmanifestitself intwoways:
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WhatisLooseness?
Mechanicalloosenesscanbeeitheroftwotypes: RotatingLooseness:Arotatingloosenessiscausedbyexcessiveclearance betweenrotatingandstationaryelementsofthemachinesuchasinabearing.
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LoosenessintheSpectrum
RotatingLooseness Excessiveclearanceinsleeveandrollingelementbearings(bearinglooseness)will produceharmonicsof1Xthatcanextendinsomecasesabove10X Excessivejournalbearingclearancecanproduceharmonicsof0.5Xasshown.They arecalledhalfordercomponentsorsubharmonics.Theycanbeproducedbyrubsand severeimpacting.
1X 2X 3X 1X 4X
.5X
1.5X
3X
2.5X
4.5X 5.5X
4X
BearingTonesinSpectra
Themostimportantfactaboutbearingtonesisthattheyarenonsynchronous i.e.,theyarenotatthesamefrequencyasanyoftheharmonics oftheRPM. Theillustrationshowsbearingtonesatabout3.2and6.4orders:
VdB
Orders
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CausesofBearingFailure
Bearingconditiondegradesforanumberofreasons: Heavierthananticipatedloading Inadequateorincorrectlubrication Ineffectivesealing Shaftmisalignment Incorrectfit
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TypicalBearingWearProgression
120 110 100 90 80 70 60 0 120 110 100 90 80 70 60 0 1 2 3 4 5 6
Broadbandnoiselevel increasesasbearingfailsto carryload Excessivebearingtemps Lubricationloss
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VdB
MachineWithoutBearingProblems
VdB
MachineWithLateStageBearingProblems
Orders
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Randomnoiseintroduced (haystack)aswearprogresses
LetsReview
Vibrationprovidestheearliestindicatorofmachine condition Vibrationaddressesallthemovingpartsofrotating equipment andcanidentifyrootcause Savestimebyaddressingproblemsearlier Savesmoneybyreducingsparepartsinventories
BUT
Upfrontstartupcosts(equipment,training,human resources)canbesignificant Spectraanalysisandmachinediagnosisstillcomplex CulturalchangeoftennecessaryforPdM
2010 Fluke Corporation Introducing 810 Vibration Tester 23
LetsReview
What if there was a way to understand machine condition With little training With existing maintenance resources With minimal upfront cost At a glance?
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Flukeredefinesmechanicaltroubleshootingwith810VibrationTester
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VibrationTestingin3SimpleSteps
Vibrationtestinghasneverbeeneasier
The810asksforbasicmachineinformationcustomersalreadyknow.ItsonboardInfo featuregivesfieldtipsforsettingupandtakingmeasurementslikeapro
Fluke810fitseasilyintocustomers maintenanceroutine
Useittoquicklytroubleshootproblemsormonitormachineconditions
Fixitrightthefirsttime
Withthepressofabutton,theFluke810identifiestherootcause,itslocation,andhow severetheproblemis
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Fluke810UsesAvailableData
Fluke810requiresthesameinformationa vibrationanalystneeds Componenttypes(motors,pumps,etc) Rotatingshaftspeed Itautomaticallysetsupthemeasurements necessarytoperformitsdiagnosis
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DiagnosesFourMostCommonFaults
Covers~80%ofmechanicalfailures
BearingCondition
Misalignment
Unbalance
Looseness
Useonthemostcommonindustrialmachinery Motors(AC/DC, HP+) Fans Blowers BeltsandChainDrives Gearboxes Couplings Pumps(Centrifugal,Piston,SlidingVane,Propeller,Screw,RotaryThread/Gear/Lobe) Compressors(Piston,Centrifugal,Screw) ClosedCoupledMachines Spindles 810cannot beusedon Turbines Centrifuges(Purifiers) Diesel/gasenginesandgenerators Beveledgearboxes
810VibrationTesterFeatures
Features Onboarddiagnosisandlocationofthefour mostcommonstandardmechanicalfaults: bearings,looseness,misalignment, unbalanceandother(nonstandardfaults) Faultseverityscalewithfourseveritylevels: Slight,Moderate,Serious,andExtreme Prioritizedrepairrecommendations Diagnosticdetailsincludecitedpeaksand vibrationspectra ContextSensitiveHelp 2GBexpandableonboardmemory Dataexport(viaUSBconnection)formore detailedAnalysis Lasertachometerforaccuratemachine runningspeed 100mV/gTEDStriaxialaccelerometer Datastorageandtrackingwithincluded VIEWERSoftware Languages:English,French,German,Italian, Portuguese,Spanish,Japanese,Simplified Chinese
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810VibrationTester ProductOverview
General Specifications: Multilingual interface 2GBmemory, expandablewith additionalSD Card 8hrbatterylife, rechargeable VGAColorTFT Display
Supportssingle andtriaxial accelerometer inputs MiniUSBPC Connection Laser Tachometer input OnboardContextSensitiveHelp
Fluke810sDiagnosticEngine Howdoesitwork?
Traditionalvibrationanalysistakesalongtermview,whereabaseline conditionisestablishedandamachinesconditioniscomparedover timetotheoriginalbaseline. Fluke810feedsthesetupandmeasurementdataintoasetof powerfulalgorithmstoidentifyamachinesmechanicalfaults Fluke810usesaninnovativesyntheticbaseline todeterminefault severity
DiagnosticEnginemarksabnormalpeaks
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FirstStep SettingupaMachine
Machinesetupsareeasyto build,saveandrecall ASetupWizardguidesthe userthroughtheprocess GarbageIn,GarbageOut: Goodmachinesetups promotebetterdiagnoses
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MachineSetup
LaserTachometer
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AnExampleMachineSetup
HereisanexampleofthelistofquestionsthattheTesterwill askforatypicalpumpcoupledtoanACMotor: MachineName:Pump1 ACMotor NoVariableFrequencyDrive RPM:1800(Minimum200RPM) HP:40 MotorMounting:Horizontal MotorBearingType:RollerBearing NextComponent:FlexibleCoupling DrivenComponent:CentrifugalPump Impellerissupportedby:TwoBearings NumberofVanes[optional]:5
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Review SettingUpaMachine
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Step2 Takingapropermeasurement
2 1
TakingvibrationreadingsisfastandeasywiththeFluke810striaxialsensoranduser friendlyinterface.
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SensorPlacement
SensorPlacement
Thenumbersatthetopofthedrivetrainimage indicatemeasurementlocations.Locationnumbering followstheflowofenergy. MeasurementTipsformeasurementlocation: Forconsistentdiagnoses overtime,youmust placethetriaxialsensorattheexactsamelocation onamachineandwiththesameorientation. Donottakebearingmeasurementsfroma foundationorfabricatedbase. Donotmistakeseallocationsforabearing measurementlocationonpumps. AttachtheSensortoaclean,flat,baremetal surfaceifpossible.Thicklayersofpaint,grease, oil,orothermatterreduceboththeholdingforce ofthemagnetandthehighfrequencyresponseof thesensor. Avoidmountingthesensoronthinsurfaceareas, suchasfanshroudsandcoolingfins.
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SensorOrientation
SensorcablePERPENDICULARtoSHAFT
SensorcableALIGNEDwiththeSHAFT
MountingOptions
Advantages:Highestfrequencyresponse,veryrepeatabledata overtime. Disadvantages:Lesspracticalforwalkaround troubleshootingduetotimeneededtoscrew/unscrewthe Sensorfrommachinery,oftendifficulttotapaholeinthe desiredmeasurementlocation. Advantages:Highfrequencyresponseapproachingthatofa studmountwithouthavingtotapahole,veryrepeatabledata overtime. Disadvantages:Lesspracticalforwalkaround troubleshootingduetotimeneededtoscrew/unscrewthe Sensorfrommountingpad.
Review Takingapropermeasurement
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DissectingtheDiagnosis
DiagnosisDetails CitedPeaks
CITEDPEAKS:Mechanicalfaultsaredetectedatcertainrunningspeedsor frequenciesinthespectra.
CitedPeak
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DiagnosisDetails Spectra
Review InterpretingtheDiagnosis
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ViewerPCSoftware
VIEWERSoftwareenablestheuserstouploadtheirmachinedata(machine setupsanddiagnosticdata)tostore,keeptrackandviewingreaterdetail. AlsouserscanusethePCtosetupmachineryfastandeasy.
TransfermachinedatatoandfromtheTester Exportmachinedataforadditionalexpertanalysis
Create,edit,deletemachinesetupseasilywiththekeyboard
Reviewfullmachinediagnosis, Viewspectrainfulldetail
Modifyapplicationsettings(e.g.language,date/time,units,subunits,etc.
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Transfer:Import/ExportMachineSetup
ImportMachineSetupscreatedintheTestertotheViewersoftware ExportMachineSetupscreatedinthePCtotheTester
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Transfer:ImportDiagnosticDataMachineSetup
Importmeasurementdatafromthe810tothePCforfurtheranalysis
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Transfer:ExportDiagnosticData
Wantasecondopinion?Exportdiagnosticinformationtoametafilefor independentanalysis
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Transfer:ExportFaultDatato.pdf
Exportyourdiagnosticdatatoa.PDFformatreport
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MachineSetup
CreateandmanageyourmachinesetupsintheViewersoftware,thensyncit
upwiththe810VibrationTester
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ViewDiagnosis
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ViewDiagnosis
ViewDetailsofCitedPeaks
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ViewDiagnosis Spectra
Viewspectraacrossthethreedifferentdimensions(axial,radial, tangential)andoverhighandlowRanges
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Everythingyouneed outofthebox
Fluke810includeseverythingyouneedto getstarted: VibrationTester Lasertachometerwithpouch TriaxialTEDSaccelerometer(sensor) Quickdisconnectcable Sensormountingpadkitwithadhesive USBcable ViewerPCsoftware Shoulderandhandstraps Hardcarryingcase QuickReferenceGuide GettingStartedGuide UserManualCD FREE Product/ApplicationTrainingDVD (availableseparately) ListPrice:$7,999
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Fluke810andYourMaintenanceRoutine
Use the Fluke 810 Vibration Tester to: Troubleshoot and identify the root cause Confirmrepairspreandpostmaintenance Commissionnewequipment Checkequipmentafterinstallation Providequantifiableproof Maketherightdecision repairorreplacement? Prioritizeandplanrepairactivities Anticipateequipmentfailures Takecontrolofyoursparepartsinventory Trainneworlessexperiencedtechnicians
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Fluke810PaysforItselfAndThenSome
CostofDowntime/Repair
1.Netincomeperhourofoutputforproductionlineorothercriticalprocess 2.Calculatetheaveragedowntime(duetomechanicalfailures)foreachequipment failureandnumberofeventsperyear. 3.Multiplytheresultsofstep1bybothvaluesinstep2. 4.Estimatelabor(overtime)andequipmentpartscostperdowntimeincident 5.Addstep3andstep4.Thisistheannualcostinlostrevenueplusrepaircosts
Cost(RTF)
$20,000/hr(critical&noncriticalmachinefailures) 8hrsdown,5motors,1x/yr ($20,000*8)*5=$800,000 $30/hr*8hrs*2techs=$480+$5000/motor=$5480 $805,480(duetocritical/noncriticalfailures)
CostofProgramImplementation
1.CostofFluke810 2.Averagecostofdedicated,experiencedvibrationtechnician(FTE)(Assume1man hour/motor/month) 3.Averageupfrontequipmenttrainingcosts+maintenancetraining 4.Addsteps1throughstep3.Thisisthetotalfirstyearcostofprogramstartup
Cost
$7,999 $0(Useexistingtechnicianresources noincrementalcost) $0(TrainingDVDincluded noincrementaltrainingcosts) $7,999
VibrationTestingPayback
1.Assume50%ofunplanneddowntimeandrepaircostssavings 2.ReturnonInvestment&PaybackofFluke810(totalcostperyear/totalsavings peryear)
Cost
$805,480*50%=$402,740 $7,999/$402,740=1wk
FlukeMakesVibrationTestingEasier
WiththeFluke810,vibrationtestingiswithinreach Itseasytouse Itgivesyouanswerswhenyouneedthem Itincludeseverythingyouneedtogetstarted immediately Youwillunderstand Rootcauseoffaultsandfixitrightthefirsttime Severityoffailuresandprioritizeyourrepairs Locationoffaultsandfocusyourrepairwork ItrequiresminimalupfrontinvestmentbuttheROIis significant
2010 Fluke Corporation Introducing 810 Vibration Tester 59
Fluke810VibrationTester
GetAnswersNow.
Visitwww.fluke.com/machinehealth formoreinformation
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