Machinery Condition Monitoring

M E HOQUE
 Types of machines

Motors
Pumps
Fans
Gearboxes
Engines Rotating
Compressors
Or
Steam Turbines
Generators
Reciprocating Machines
Gas Turbines
Hydro Turbines
 Proactive Predictive Reactive

PP
Lubrication Excellence
Precision Maintenance
Alignment, Balance, etc.
Select Suppliers
Supplier Specifications
Equipment Performance

Metrics
Equipment Ranking
RCM We are here
TPM
RCA/FMEA
RCD
Training Programs
Written Procedures
Job Planning/Scheduling
CMMS System FF
Time
Machine Condition Chart
 Condition Monitoring

Condition monitoring is the process of monitoring a

parameter of condition in machinery, such that a
significant change is indicative of a developing failure. It
is a major component of Predictive Maintenance
(PdM). The use of conditional monitoring allows
maintenance to be scheduled, or other actions to be
taken to avoid the consequences of failure, before the
failure occurs.
 Machine condition monitoring technologies

Oil Analysis
Industrial requirements for
machine condition monitoring

• Non-intrusive
measurements

• Early detection to reduce

cost Condition Vibration
Ultrasound Monitoring
Analysis
• Multiple technologies for Technologies
complete assessment

Infrared
Thermography
 Condition Monitoring
For your Plant
Vibration
Analysis Oil Analysis

Thermal Ultrasound
Analysis Analysis

If you think this is your plant, then your plant is stand on this 4 technologies
 What Is Vibration ?

Vibration is a "back and forth" movement of a structure. It can also be

referred to as a "cyclical" movement
 Machine failures

are very costly…

sometimes spectacular,

…and the VIbration is a common

cause of failure
 Vibration Analysis

More than 20 years ago someone made the statement, “The

vibrations produced in a machine are the best indication of the
machine’s health.” This statement still holds true today. Of all the
predictive maintenance (PdM) technologies, vibration analysis
remains the best measure of machine health. This is true because
vibration monitoring can alert us to so many different conditions
that may indicate potential machine failures. Unbalance,
misalignment, bearing faults, resonance, looseness, cavitations and
electrical problems are just a few of the many problems that can be
detected with vibration monitoring.
Common Problems that Generate
Vibration

1. Misalignment
2. Unbalance
3. Worn belts & pulleys
4. Bearing Defects
5. Hydraulic Forces
6. Aerodynamic Forces
7. Reaction Forces
8. Reciprocating Forces
9. Bent Shafts
10.Rubbing
11.Gear Problems
12.Housing Distortion
13.Certain Electrical Problems
14.Frictional Forces
 What we Measure for
Vibration Analysis

Amplitude: How Much Movement
Occurs or severity of the vibration.
Amplitude measures as
1. Displacement: mm, mils (0.001”)
2. Velocity: mm/sec, in/sec
3. Acceleration: G’s (1g= Force of
gravity) or rms (root mean square)
Frequency: How Often The Phase: In What Direction Is
Movement Occurs. How many The Movement. It also called
"cycles" in a period of time: a phase angle.
second or a minute
Unit: Degree
Unit: Cycle per second (Hz)
Cycle per Minute (CPM)
 How we measure Vibration

Axial: Axial direction is always on Vertical: A Transducer Horizontal: A Transducer

the parallel to the shaft axis. Mounted Vertically "Sees“ Mounted Horizontally "Sees"
Only Vertical Movement Only Horizontal Movement
 Vibration Transducer
Sensors…Transducers…Probes…What is it?
….It basically converts mechanical vibration to
an electrical signal

Accelerometer
Displacement Velocity Charge Type &
Shaft Riders
Transducer
Line Drive
Proximity Probes Constant Voltage &
(Eddy Current Probes) Constant Current
 Mounting Direction

Vertical Radial
Vertical

Axial

Radial Horizontal

Horizontal
 Mounting Direction
Hori. Vert. Vert.
Hori.

Axial Axial

For detail study of vibration dynamics of machine

– vertical, horizontal and axial at each bearing location

For monitoring – one point per bearing and add axial when
There is a thrust bearing or axial potential faults eg. misalignment
 Machinery Health Monitoring
Strategy
Application at Typical Plant
Total # Machines 2,500
Typical Industrial Process Plant

Turbines
Generators ~125 Machines 5% Online Solutions for
Compressors Critical critical machinery

Motors 25%
Wireless
Pumps ~1375 Machines Essential
Transmitters
Fans
Gears
30%
Important

20%
~500 Machines Secondary
Multi Technologies
20% Portable Solutions
~500 Machines Non-Essential
 By the Medical ECG we
know the condition of
our Heart

By the CSI 2140 we

check your Machinery
Health Condition
 Data Representation

Wave Form Plot or Domain Plot FFT Spectrum Plot

Waterfall Plot Orbit Plot

 FFT Spectrum Plot for some
Problems

Unbalance Misalignment Structural Looseness Bearing Looseness

Structural Resonance Sleeve Bearing Gear Problem Pump Cavitation

Looseness/Rubs Misalignment

X=RPM=CPM CPM=Cycle per minute=60Hz

1X=1xRPM=1xCPM
2X=2xRPM=2xCPM
3X=3xRPM=3xCPM
Demonstration on Vibration Analysis
Technology
CSI 2140 Machinery Health Analyzer
Five Inputs = Four Channels + Tacho

Five Inputs:
✓ Channel 1
✓ Channel 2
✓ Channel 3
✓ Channel 4
+
✓ Tachometer
4 Channel Volts + Tach

4 Channel Accel+ Tach

Multiple Live Plots – Up to 8!