SKF today

39,000 people 90 plants 42,000 MSEK (4.5 Billion EUR)

In 140 countries >6200 Distributors 1,400 Employees in Reliability Systems

2006-12-07 ©SKF Slide 2 [Code]

SKF [Organisation]
Fundamentals of Machine
Condition

2006-12-07 ©SKF Slide 3 [Code]

SKF [Organisation]
Introductions

Name
Work area
Experience
Course expectations
Specific machinery or maintenance problem?

2006-12-07 ©SKF Slide 4 [Code]

SKF [Organisation]
Seminar agenda

Day 1
• Basics of Condition Based Maintenance

• What is Vibration?

• Sensors

Day 2
• Spectrum Analysis

• Establishing Vibration Measurements

2006-12-07 ©SKF Slide 5 [Code]

SKF [Organisation]
 Course objective

To introduce the concepts of condition-based maintenance,

with an emphasis on the use of machinery vibration as a tool to
determine machine health and identify root cause problems

2006-12-07 ©SKF Slide 6 [Code]

SKF [Organisation]
Evolution of Maintenance Techniques…

Concurrent Engineering (LCC)

Operator Maintenance (TPM)
Reliability Engineering (RCM)
Diagnostics

Predictive Maintenance

Systematic Planning & Scheduling

Preventive Maintenance

Inspect, Lubricate

Repair After Failure

30's 40's 50's 60's 70's 80's 90's '00's '10's

2006-12-07 ©SKF Slide 7 [Code]

SKF [Organisation]
Cost of Maintenance

30
Cost of Maintenance: US$/HP/Year

25

20 Reactive
15 $18.00 Preventive
10 $13.00 Predictive
5 $ 8.00
0
Type of Maintenance Program

"The Power of Prediction", Industry Week, July 4, 1994

2006-12-07 ©SKF Slide 8 [Code]

SKF [Organisation]
 Benefits of Reliability
World Class Average

‰ Average life of electric motors > 15 yrs < 10 yrs

‰ Mean time between repairs for pumps > 6 yrs < 3 yrs

‰ Average vibration levels < 0.1 in/sec > 0.3

‰ Overtime, percent of total hours worked <3% > 10 %

‰ Emergency work < 5% > 15 %

‰ Total maintenance cost < 2% > 3%

“Reliability impacts safety, environmental, quality, service, cost”

Source: Bob Taylor – SMRP Key Note

2006-12-07 ©SKF Slide 9 [Code]

SKF [Organisation]
 Predictive Maintenance Techniques - Typical

Vibration Analysis 75%

Oil Analysis 13%

Thermography 8%

Electrical Analysis 4%

• Motor current analysis etc.

2006-12-07 ©SKF Slide 10 [Code]

SKF [Organisation]
 Maintenance Strategies

Corrective
Total Uptime

Preventive
Total Uptime

Predictive
Total Uptime

Proactive Reliability
Maintenance
Maximum Uptime

= Uptime = Planned = Unplanned downtime

periods downtime (breakdowns)

2006-12-07 ©SKF Slide 11 [Code]

SKF [Organisation]
Condition-Based Maintenance…

Principles
• Monitor a variety of machine conditions to identify a change in health
• Schedule repairs in advance to reduce cost and impact on operation

2006-12-07 ©SKF Slide 12 [Code]

SKF [Organisation]
Condition-Based Maintenance

Examples of Condition-Based Parameters

• Vibration
• Bearing temperature, thermography
• Process variables – flows, pressures, etc.
• Lubricant condition
• Product quality
• Motor current, ultrasonic
• Ultrasonic thickness gauging

2006-12-07 ©SKF Slide 13 [Code]

SKF [Organisation]
The ideal condition-based model

• Identify a potential problem

• Verify the problem – diagnosis and analysis
• Identify root cause if appropriate
• Issue corrective work order to fix problem and address
the root cause
• Verify the correction and adjust acceptance limits up or
down

2006-12-07 ©SKF Slide 14 [Code]

SKF [Organisation]
The four basic steps - detection

Detection - routine vibration data collection, where

readings on a machine, machine component, or structure
are compared to alarm limits specifically created for the
machine.
Analysis
Correction
Verification

2006-12-07 ©SKF Slide 15 [Code]

SKF [Organisation]
The four basic steps – analysis

Detection
Analysis - utilize advanced tools and techniques, first to
confirm the diagnosis of the problem, and second to
identify the most likely vibration-based root cause.
Correction
Verification

2006-12-07 ©SKF Slide 16 [Code]

SKF [Organisation]
The four basic steps - correction

Detection
Analysis
Correction - actions that can be executed while the
machine is operating or when there is an opportune time,
such as a planned production outage
Verification

2006-12-07 ©SKF Slide 17 [Code]

SKF [Organisation]
The four basic steps – verification

Detection
Analysis
Correction
Verification - ensure that the repair has been made, the
root cause has been addressed, and that no new problems
were introduced during the repair

2006-12-07 ©SKF Slide 18 [Code]

SKF [Organisation]
 Typical Machine Service Life…

Need TEMPORARY High Intensity

“Infant Mortality” Condition Monitoring & Evaluation
Wear-In “Wear-Out”
Period Period

Manufacturer’s Recommended Service Life

at Rated Load & Conditions

• Plant Start-Up • End of Life Cycle Monitoring

• Post Installation Testing • Intensive Monitoring of
Machinery in Distress
• Post Maintenance Verification
• Post Machine Rebuild
2006-12-07 ©SKF Slide 19 [Code]
SKF [Organisation] Wireless
System
Output of Predictive Maintenance Program…

Protection
Surveil-
lance

Portable

Years Months Weeks Days Hours Minutes

Collects More Data Than a Portable, Easier to Install and Move than a
Permanently Installed On-Line System

2006-12-07 ©SKF Slide 20 [Code]

SKF [Organisation]
How deterioration advance towards failure

Traditional Bathtub Curve

Early Failure
Failure Rate

Normal Incidence Preventive

Maintenance

Time

2006-12-07 ©SKF Slide 21 [Code]

SKF [Organisation]
Add condition-based…

Application of Condition-Based Maintenance

Early Failure
Repair on Condition
Failure Rate

Normal Incidence

Improvement
Time

2006-12-07 ©SKF Slide 22 [Code]

SKF [Organisation]
The Condition-Based Maintenance cycle

adjust alarm levels Periodic

(improve) Monitoring

increase measurement frequency

repair measurement
equipment exceeds no
alarm limit?

yes

schedule analyze
repair(s) problem

2006-12-07 ©SKF Slide 23 [Code]

SKF [Organisation]
How deterioration advances toward failure

Shutdown
Deterioration

Alarm

Level needs to
be high enough
to avoid false
alarms

Lead Time
Running Time

2006-12-07 ©SKF Slide 24 [Code]

SKF [Organisation]
Trend graph

.500
Repair Just
Prior To Failure Upcoming
Maintenance
.400
Maintenance Maintenance
Year 1 Year 2
Alert (0.314)
.300

.200

.100 New Baseline

Annual Life Cycle of Limestone Material Blower

.000
05 09 12 04 08 11 03 07 10
23 10 29 18 06 24 14 02 20
1990 1990 1990 1991 1991 1991 1992 1992 1992

2006-12-07 ©SKF Slide 25 [Code]

SKF [Organisation]
 Maintenance philosophies

Run-to-failure
• Large inventories, machines that cost more to maintain than replace

Preventive
• Oil changes, scheduled activities

Condition-based
• Trending, determine the current condition of machinery as it runs, in order to schedule
necessary repairs on a timely basis

Proactive
• Eliminate or reduce the sources of failures through craftsmanship and the use of the highest
quality components and parts , root cause correction, continuous improvement

2006-12-07 ©SKF Slide 26 [Code]

SKF [Organisation]
How Condition-Based
Maintenance Programs Work

2006-12-07 ©SKF Slide 27 [Code]

SKF [Organisation]
 Condition Monitoring decisions

• What machinery do I monitor?

• What measurements do I perform on the selected
machinery?
• How often do I perform the selected measurements?
• What type of PdM equipment do I monitor with?

2006-12-07 ©SKF Slide 28 [Code]

SKF [Organisation]
Selecting machinery to monitor

• Problem machinery
• Affect on production
• Probability of failure
• Personnel safety
• Manning level

2006-12-07 ©SKF Slide 29 [Code]

SKF [Organisation]
 Machinery classifications

Critical – On-Line Protection Systems

• Essential, un-spared equipment
• Progress very rapidly toward catastrophic failure, therefore requires very fast
data collection and automatic shutdown features

Toxic, un-spared, high polling requirement (no shut-down

protection required) – Surveillance Systems
• Hazardous/unsafe environments
• Lack of manpower
• More frequent monitoring (continuous data collection)
Balance of plant - Portable Systems
• Non critical surveillance
2006-12-07 ©SKF Slide 30 [Code]
SKF [Organisation]
 Critical equipment

• Essential, un-spared machines

• High maintenance dollars
• High impact on production output
• Progress very rapidly toward catastrophic failure
• Critical failure causes high safety risk
• Vibration/TSI monitoring is a integral part of operating critical
equipment
• run up / run down

2006-12-07 ©SKF Slide 31 [Code]

SKF [Organisation]
 Toxic, un-spared, high polling

Automated on-line surveillance systems

• Hazardous environments
• Require more frequent data collection
• Network capabilities
• Consistent data collection
• permanently mounted sensors
• No automatic shut-down features

2006-12-07 ©SKF Slide 32 [Code]

SKF [Organisation]
 “Balance of plant” equipment

Portable surveillance systems

• Require less frequent monitoring
• every week, month, quarter
• Non-critical machinery
• Low safety risk
• Failure has little effect on production
• Low maintenance costs

2006-12-07 ©SKF Slide 33 [Code]

SKF [Organisation]
 Industry specifics

Power generation
• Mostly protection systems

• Not just surveillance but an integral part of machinery

• Use vibration monitoring (TSI) to start up and operate machinery
Pulp and paper
• Mostly on-line monitoring

• Using on-line monitoring to control quality

• Also a need for protection system

Petrochemical
• Mostly on-line monitoring

* All three also use Portable monitoring for balance-of-plant equipment

2006-12-07 ©SKF Slide 34 [Code]

SKF [Organisation]
 How often do I measure?

• Machinery that have experienced past problems, or for

which problems have historically developed quickly,
require shorter measurement intervals

• For machinery with a good, reliable operating history,

measurement intervals are longer

• Continuous vs. Periodic monitoring

2006-12-07 ©SKF Slide 35 [Code]

SKF [Organisation]
Condition Monitoring Techniques…

Vibration Analysis
Modal Lubricant
Analysis Analysis

Condition
Ultrasonic Monitoring Alignment
Gauging
Technologies

Balancing
Infrared
Thermography
Motor Analysis

2006-12-07 ©SKF Slide 36 [Code]

SKF [Organisation]
 What measurements do I perform?

Vibration
The “key” to detecting and isolating
Temperature
specific faults is to perform the
Lube Oil appropriate measurement (or
Process measurements) that best detects
the expected faults.
• Pressure
• Flow
• Speed

2006-12-07 ©SKF Slide 37 [Code]

SKF [Organisation]
 Lube oil analysis

Evaluates
• Oil degradation characteristics
• Wear rates
• Contamination levels
Warns of an increase in foreign substances
Detects metallic particles carried onto the
oil stream

2006-12-07 ©SKF Slide 38 [Code]

SKF [Organisation]
Basic lubricant analysis

• Spectrochemical & physical properties

• Wear particle analysis
• Particle counts

2006-12-07 ©SKF Slide 39 [Code]

SKF [Organisation]
Concepts/Implementing Slide 56

Trend of wear particles versus vibration

100
90 Scale 0-100%
80 (Normalized)
70

60
ppm Cu
50
40

30 Velocity (ips)
20

10

0
Time Scale = 7 Months 11 Days
(A) SET: 1801 COMPRESSOR 1801 COMPRESSOR
POINT ID: GAS COMP 1801-2V3 COMPRESSOR
FULL SCALE: 0.5 UNITS: IPS
STANDARD DEV: 0.21712 MEAN: 0.25757 HIGHEST: 00:00:00 0.66
(B) SET: 1801 OIL SUMP 1801 COMPRESSOR
POINT ID: 1801 OIL PPM CU Cu (ppm)
FULL SCALE: 500 UNITS: ppm Cu
STANDARD DEV: 340.392 MEAN: 422.6 HIGHEST: 12:36:36 809

2006-12-07 ©SKF Slide 41 [Code]

SKF [Organisation]
 Temperature

• A useful indicator of mechanical condition,

friction, or the load applied to a specific
component, such as a thrust bearing

• Thermography uses infra red scanners, similar

to video cameras, to detect differences in surface
temperatures

2006-12-07 ©SKF Slide 42 [Code]

SKF [Organisation]
 Temperature and Thermography

• A useful indicator of
mechanical condition, friction,
or the load applied to a specific
component, such as a thrust
bearing

• Thermography uses infra red

scanners, similar to video
cameras, to detect differences
in surface temperatures

2006-12-07 ©SKF Slide 43 [Code]

SKF [Organisation]
Ultrasonic detection

Senses high frequency

sounds produced by
operating equipment,
liquid, air, or gas leaks and
electrical discharges

2006-12-07 ©SKF Slide 44 [Code]

SKF [Organisation]
Vibration-based condition monitoring options

Protection systems
• Simultaneous data collection

• Protect critical equipment

• Provide automatic shutdown features

Surveillance systems (on-line monitoring)

• Periodically monitor equipment

• Useful in harsh environments

• Provide predictive maintenance features

Portable systems for periodic data collection

• Balance of plant

2006-12-07 ©SKF Slide 45 [Code]

SKF [Organisation]
 Hand-held instruments

• Carried by machinery
maintenance
personnel.
• When placed in
contact with vibrating
machinery, provide a
display of vibration
data.
• Vibration levels are
assessed on the spot
for normal or
abnormal machinery
vibration conditions.

2006-12-07 ©SKF Slide 46 [Code]

SKF [Organisation]
Hand-held meter with storage capabilities

• Data storage capabilities

• ROUTE data collection / upload to software
• ODR use (record process parameters and vibration data)

2006-12-07 ©SKF Slide 47 [Code]

SKF [Organisation]
 Portable data collectors / analyzers

• Periodically collect and record

machinery data (ROUTEs)
• Record / display trend plots, FFT
spectra, and time waveforms
• In-the-field analysis
• Interface with vibration analysis
database and management
software

2006-12-07 ©SKF Slide 48 [Code]

SKF [Organisation]
On-line condition monitoring units (CMU)

Machine
automated monitoring using
sensors permanently attached sensor
to the monitored machine

interfaces with vibration analysis,

database management software

CMU
Software

2006-12-07 ©SKF Slide 49 [Code]

SKF [Organisation]
 On-line protection systems

• Automated,
continuous monitoring
• Earliest detection
• Relays - for alarms or
machine shut down
• Sleeve bearings
• Large, high speed,
critical machinery

2006-12-07 ©SKF Slide 50 [Code]

SKF [Organisation]
 Concepts/Implementing Slide 28

Database management software

• Easy measurement
setup
• Alarm comparisons
• Full featured analysis
plots (trend, FFT,
waveform)
• Report generation
• Easily share data

2006-12-07 ©SKF Slide 51 [Code]

SKF [Organisation]
Root cause analysis and correction

A comprehensive proactive vibration program is:

• Detection of problem machinery or those with levels that may be
damage causing
• Diagnosis of the probable fault or source
• Analysis of the machine to confirm the diagnosis
• Determination of corrective measures
• Generation of corrective and proactive work recommendations
• Verification of the correction

2006-12-07 ©SKF Slide 52 [Code]

SKF [Organisation]
Quick review

QUESTIONS ?

2006-12-07 ©SKF Slide 53 [Code]

SKF [Organisation]