Howto Online Monitor Typical Assets

How to online monitor typical assets
Condensate
Boiler Paper Paper
Water or Vertical Sleeve Bearing Conveyor
Feedwater Machine Machine Recip
Lube Oil Pump Based Pump Drive
Pump Screen Press Rolls
Pumps
Steam Paper Paper Mining

Combustion Hydro Package Wind
Turbine and Machine Machine Electric
Turbine Turbine Compressor Turbine
Generator Fan Pump Rolls Rope Shovel
Large Mining
Small Tissue Machine
Forced or V-Belt Driven Cooling Tower Paper Mill SAG Mill Centrifugal
Fan with Yankee &
Induced Fan Fan Wood Chipper And Compressor
direct drive Crepe Blade
Draft Fan Ball Mills
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TRAINING
SLIDES
Emerson proprietary information
Cooling Tower Fan with 90°Gearbox and Motor
MECHANICAL FAULTS
• ELECTRIC MOTOR
1. BALANCE
2. ALIGNMENT
3. LOOSENESS
4. BEARING FAULTS (PeakVue)
FLOW
FLOW
5. MOTOR FAULTS
6. COUPLING FAULTS (PeakVue)
7. DRIVE SHAFT FAULTS (PeakVue)
• GEARBOX
1. GEARMESH FAULTS (PeakVue)
FAN BLADE
HUB
2 6 • FAN ROTOR
1. BALANCE
1 MOTOR 5 2. ALIGNMENT
DRIVE SHAFT
GEARBOX 3. LOOSENESS
3 4
• PERFORMANCE (OTHER SENSORS)
1. OPTIMAL SPEED RANGES
2. BLADE PASS PULSATIONS
3. MOTOR CURRENT DRAW/HP
4. INLET/OUTLET PRESSURE RISE
5. EFFICIENCY
6. COOLING WATER FLOW RATES
6 POINT COVERAGE 4 POINT COVERAGE FAN FOCUS
7. VENDOR SELECTION (BEST PARTS)
1. MOH – Motor Outboard Horizontal 1. MOH – Motor Outboard Horizontal 2 POINT COVERAGE What the heck is vendor selection? It’s the use of one
2. MIV – Motor Inboard Vertical 3. MIA – Motor Inboard Axial 4. FIA – Fan Inboard Axial brand or another and the difference in performance
between them. For example one brand of bearing may
3. MIA – Motor Inboard Axial 4. FIA – Fan Inboard Axial 6. FOV – Fan Outboard Vertical last longer than another brand. Or one brand of
4. FIA – Fan Inboard Axial 6. FOV – Fan Outboard Vertical lubricant runs better than another brand. Its picking
the best performing components to run in your asset
5. FOH – Fan Outboard Horizontal SPLIT FOCUS based on direct experience.
6. FOV – Fan Outboard Vertical 2 POINT COVERAGE
7. Tachometer (option) 3. MIA – Motor Inboard Axial
Emerson proprietary information 6. FOV – Fan Outboard Vertical
MENU
Fans/Blowers – SISW – with Gearbox and Motor
MECHANICAL FAULTS
FLOW
FLOW
SISW – Single Inlet Single Width • ELECTRIC MOTOR
1. BALANCE
2. ALIGNMENT
3. LOOSENESS
5. MOTOR FAULTS
• GEARBOX
IMPELLER
2 3. COUPLING FAULTS (PeakVue)
7
8 6 5 4 MOTOR
FLOW SHAFT GEARBOX
• FAN ROTOR
1. BALANCE
3 2. ALIGNMENT
3. LOOSENESS

3. ROTATING STALL
8 POINT COVERAGE 6 POINT COVERAGE 4 POINT COVERAGE 6. EFFICIENCY
1. MOH – Motor Outboard Horizontal 1. MOH – Motor Outboard Horizontal 3. MIA – Motor Inboard Axial 7. RESONANCES
2. MIV – Motor Inboard Vertical 3. MIA – Motor Inboard Axial 5. GOH – Gearbox Outboard Horizontal 8. VENDOR SELECTION (BEST PARTS)
3. MIA – Motor Inboard Axial 4. GIH – Gearbox Inboard Horizontal 7. FIA – Fan Inboard Axial
4. GIH – Gearbox Inboard Horizontal 5. GOH – Gearbox Outboard Horizontal 8. FOH – Fan Outboard Horizontal
5. GOH – Gearbox Outboard Horizontal 7. FIA – Fan Inboard Axial
6. FIH – Fan Inboard Horizontal 8. FOH – Fan Outboard Horizontal 2 POINT COVERAGE
7. FIA – Fan Inboard Axial 7. FIA – Fan Inboard Axial
8. FOH – Fan Outboard Horizontal 8. FOH – Fan Outboard Horizontal
9. Tachometer (option) Emerson proprietary information MENU
Blower – SISW with Motor
MECHANICAL FAULTS
FLOW
• ELECTRIC MOTOR
SISW = Single Inlet Single Width 1. BALANCE
2. ALIGNMENT
3. LOOSENESS
5. MOTOR FAULTS
• FAN ROTOR
1. BALANCE
IMPELLER
2. ALIGNMENT
3. LOOSENESS
2
5
6 4 MOTOR 1
FLOW SHAFT
3 2. BLADE PASS PULSATIONS
3. ROTATING STALL
6. EFFICIENCY
7. RESONANCES
6 POINT COVERAGE 4 POINT COVERAGE 2 POINT COVERAGE

1. MOH-Motor Outboard Horizontal 1. MOH-Motor Outboard Horizontal 5. FIA-Fan Inboard Axial
2. MIV-Motor Inboard Vertical 3. MIA-Motor Inboard Axial 6. FOH-Fan Outboard Horizontal
3. MIA-Motor Inboard Axial 5. FIA-Fan Inboard Axial
4. FIH-Fan Inboard Horizontal 6. FOH-Fan Outboard Horizontal
5. FIA-Fan Inboard Axial
6. FOH-Fan Outboard Horizontal
7. Tachometer (option)
Emerson proprietary information MENU
Blower – SISW with V-Belt Drive and Motor
MECHANICAL FAULTS
• ELECTRIC MOTOR
FLOW
SISW – Single Inlet Single Width 1. BALANCE
2. ALIGNMENT
3. LOOSENESS
5. MOTOR FAULTS
• FAN ROTOR
1. BALANCE
IMPELLER
2. ALIGNMENT
3. LOOSENESS
5
6 4
FLOW SHAFT
3. ROTATING STALL
2 4. MOTOR CURRENT DRAW/HP
1 MOTOR 6. EFFICIENCY
7. RESONANCES
3 8. VENDOR SELECTION (BEST PARTS)

1. MOH-Motor Outboard Horizontal 1. MOH-Motor Outboard Horizontal 5. FIA-Fan Inboard Axial
2. MIV-Motor Inboard Vertical 3. MIA-Motor Inboard Axial 6. FOH-Fan Outboard Horizontal
3. MIA-Motor Inboard Axial 5. FIA-Fan Inboard Axial
4. FIH-Fan Inboard Horizontal 6. FOH-Fan Outboard Horizontal
5. FIA-Fan Inboard Axial
6. FOH-Fan Outboard Horizontal
Blower – DIDW with Gearbox and Motor
FLOW
FLOW
MECHANICAL FAULTS
FLOW
• ELECTRIC MOTOR
1. BALANCE
2. ALIGNMENT
3. LOOSENESS
5. MOTOR FAULTS
DIDW – Double Inlet Double Width • GEARBOX

IMPELLER
8 6 5 4 MOTOR 1 • FAN ROTOR

HUB SHAFT GEARBOX 1. BALANCE
2. ALIGNMENT
7 3 3. LOOSENESS

3. ROTATING STALL
8 POINT COVERAGE 6. EFFICIENCY
1. MOH – Motor Outboard Horizontal 6 POINT COVERAGE 4 POINT COVERAGE 7. RESONANCES
2. MIV – Motor Inboard Vertical 1. MOH – Motor Outboard Horizontal 3. MIA – Motor Inboard Axial 8. VENDOR SELECTION (BEST PARTS)
3. MIA – Motor Inboard Axial 3. MIA – Motor Inboard Axial 5. GOH – Gearbox Outboard Horizontal
4. GIH – Gearbox Inboard Horizontal 4. GIH – Gearbox Inboard Horizontal 7. FIA – Fan Inboard Axial
5. GOH – Gearbox Outboard Horizontal 5. GOH – Gearbox Outboard Horizontal 8. FOH – Fan Outboard Horizontal
6. FIH – Fan Inboard Horizontal 7. FIA – Fan Inboard Axial
7. FIA – Fan Inboard Axial 8. FOH – Fan Outboard Horizontal 2 POINT COVERAGE
8. FOH – Fan Outboard Horizontal 7. FIA – Fan Inboard Axial
9. Tachometer (option) Emerson proprietary information 8. FOH – Fan Outboard Horizontal MENU
Blower – DIDW with Motor
FLOW
FLOW
DIDW – Double Inlet Double Width MECHANICAL FAULTS
• ELECTRIC MOTOR
FLOW
1. BALANCE
2. ALIGNMENT
3. LOOSENESS
5. MOTOR FAULTS
• FAN ROTOR
1. BALANCE
IMPELLER
2. ALIGNMENT
2 3. LOOSENESS
6 4 MOTOR 1
HUB SHAFT • PERFORMANCE (OTHER SENSORS)
5 3 2. BLADE PASS PULSATIONS
3. ROTATING STALL
6. EFFICIENCY
7. RESONANCES
6 POINT COVERAGE 4 POINT COVERAGE FAN FOCUS

1. MOH – Motor Outboard Horizontal 1. MOH – Motor Outboard Horizontal 2 POINT COVERAGE
2. MIV – Motor Inboard Vertical 3. MIA – Motor Inboard Axial 5. FIA – Fan Inboard Axial
3. MIA – Motor Inboard Axial 5. FIA – Fan Inboard Axial 6. FOH – Fan Outboard Horizontal
4. FIH – Fan Inboard Horizontal 6. FOH – Fan Outboard Horizontal
5. FIA – Fan Inboard Axial
6. FOH – Fan Outboard Horizontal
Single Suction Pump with Gearbox and Motor
NOTE: it is beneficial on pumps and fans to measure pressure pulsations from the discharge. To MECHANICAL FAULTS
do this requires mounting a dynamic pressure sensor in the discharge piping. Usually this • ELECTRIC MOTOR
pressure sensor should be located the equivalent of several discharge pipe diameters 1. BALANCE
downstream. 2. ALIGNMENT
3. LOOSENESS
5. MOTOR FAULTS
FLOW
• GEARBOX
8 6
• PUMP ROTOR
IMPELLER
5 4 MOTOR 1
FLOW SHAFT GEARBOX 1. BALANCE
2. ALIGNMENT
7 3 3. LOOSENESS

2. VANE PASS PULSATIONS
3. CAVITATION (PeakVue)
8 POINT COVERAGE 6 POINT COVERAGE 4 POINT COVERAGE 6. EFFICIENCY
1. MOH – Motor Outboard Horizontal 1. MOH – Motor Outboard Horizontal 3. MIA – Motor Inboard Axial 7. SEAL INTEGRITY
2. MIV – Motor Inboard Vertical 3. MIA – Motor Inboard Axial 5. GOH – Gearbox Outboard Horizontal 8. RESONANCES
3. MIA – Motor Inboard Axial 4. GIH – Gearbox Inboard Horizontal 7. PIA – Pump Inboard Axial 9. VENDOR SELECTION
4. GIH – Gearbox Inboard Horizontal 5. GOH – Gearbox Outboard Horizontal 8. POH – Pump Outboard Horizontal
5. GOH – Gearbox Outboard Horizontal 7. PIA – Pump Inboard Axial
6. PIH – Pump Inboard Horizontal 8. POH – Pump Outboard Horizontal PUMP FOCUS
7. PIA – Pump Inboard Axial 2 POINT COVERAGE (1 – 9420)
8. POH – Pump Outboard Horizontal 7. PIA – Pump Inboard Axial
9. Tachometer (option) Emerson proprietary information 8. POH – Pump Outboard Horizontal MENU
Single Suction Pump with Motor
MECHANICAL FAULTS
• ELECTRIC MOTOR
1. BALANCE
2. ALIGNMENT
3. LOOSENESS
FLOW
NOTE: the pump bearings may be so close together 5. MOTOR FAULTS
Typical Pump that they would be both measured by 4 and 5, which 6. COUPLING FAULTS (PeakVue)
would make the split focus the best monitoring for 2
point coverage. • PUMP ROTOR
1. BALANCE
2 2. ALIGNMENT
6 4
3. LOOSENESS
IMPELLER
MOTOR 1 4. BEARING FAULTS (PeakVue)
FLOW SHAFT
5 3 • PERFORMANCE (OTHER SENSORS)

6. EFFICIENCY
6 POINT COVERAGE 4 POINT COVERAGE PUMP FOCUS 7. SEAL INTEGRITY
1. MOH – Motor Outboard Horizontal 1. MOH – Motor Outboard Horizontal 2 POINT COVERAGE 8. RESONANCES
2. MIV – Motor Inboard Vertical 3. MIA – Motor Inboard Axial 5. PIA – Pump Inboard Axial 9. VENDOR SELECTION
3. MIA – Motor Inboard Axial 5. PIA – Pump Inboard Axial 6. POH – Pump Outboard Horizontal
4. PIH – Pump Inboard Horizontal 6. POH – Pump Outboard Horizontal
5. PIA – Pump Inboard Axial
6. POH – Pump Outboard Horizontal SPLIT FOCUS
7. Tachometer (option) 2 POINT COVERAGE
3. MIA – Motor Inboard Axial
4. PIH – Pump Inboard Horizontal

Double Suction Pump with Gearbox and Motor
MECHANICAL FAULTS
• ELECTRIC MOTOR
1. BALANCE
2. ALIGNMENT
FLOW
3. LOOSENESS
5. MOTOR FAULTS
• GEARBOX
2 2. BEARING FAULTS (PeakVue)
8 6
IMPELLER
5 4 MOTOR 1
GEARBOX
• PUMP ROTOR
7 3 1. BALANCE
2. ALIGNMENT
3. LOOSENESS

8 POINT COVERAGE 6 POINT COVERAGE 4 POINT COVERAGE 2. VANE PASS PULSATIONS
1. MOH – Motor Outboard Horizontal 1. MOH – Motor Outboard Horizontal 3. MIA – Motor Inboard Axial 3. CAVITATION (PeakVue)
2. MIV – Motor Inboard Vertical 3. MIA – Motor Inboard Axial 5. GOH – Gearbox Outboard Horizontal 4. MOTOR CURRENT DRAW/HP
3. MIA – Motor Inboard Axial 4. GIH – Gearbox Inboard Horizontal 7. PIA – Pump Inboard Axial 5. INLET/OUTLET PRESSURE RISE
4. GIH – Gearbox Inboard Horizontal 5. GOH – Gearbox Outboard Horizontal 8. POH – Pump Outboard Horizontal 6. EFFICIENCY
5. GOH – Gearbox Outboard Horizontal 7. PIA – Pump Inboard Axial 7. SEAL INTEGRITY
6. PIH – Pump Inboard Horizontal 8. POH – Pump Outboard Horizontal 8. RESONANCES
7. PIA – Pump Inboard Axial PUMP FOCUS 9. VENDOR SELECTION
8. POH – Pump Outboard Horizontal 2 POINT COVERAGE
9. Tachometer (option) 7. PIA – Pump Inboard Axial
8. POH – Pump Outboard Horizontal

Double Suction Pump with Motor
MECHANICAL FAULTS
• ELECTRIC MOTOR
1. BALANCE
2. ALIGNMENT
FLOW
3. LOOSENESS
5. MOTOR FAULTS
• PUMP ROTOR
1. BALANCE
2 2. ALIGNMENT
6 4
3. LOOSENESS
IMPELLER
MOTOR 1 4. BEARING FAULTS (PeakVue)
5 3 • PERFORMANCE (OTHER SENSORS)

6. EFFICIENCY
6 POINT COVERAGE 4 POINT COVERAGE PUMP FOCUS 7. SEAL INTEGRITY
1. MOH – Motor Outboard Horizontal 1. MOH – Motor Outboard Horizontal 2 POINT COVERAGE 8. RESONANCES
2. MIV – Motor Inboard Vertical 3. MIA – Motor Inboard Axial 5. PIA – Pump Inboard Axial 9. VENDOR SELECTION
3. MIA – Motor Inboard Axial 5. PIA – Pump Inboard Axial 6. POH – Pump Outboard Horizontal
4. PIH – Pump Inboard Horizontal 6. POH – Pump Outboard Horizontal
5. PIA – Pump Inboard Axial
6. POH – Pump Outboard Horizontal

Double Suction Pump with Sleeve Bearings
NOTE: MECHANICAL FAULTS
1. The pump has sleeve bearings • ELECTRIC MOTOR
2. The motor and gearbox have antifriction bearings 1. BALANCE
3. It’s not typical to take a thrust measurement on 2. ALIGNMENT
most pumps or blowers unless they have tight 3. LOOSENESS
internal clearances. Thrust is important on turbo 4. BEARING FAULTS (PeakVue)
FLOW
equipment with tight internal clearances, such as 5. MOTOR FAULTS
turbines. 6. COUPLING FAULTS (PeakVue)
4. PeakVue can be used to look at high frequency
sleeve bearing data and could detect low or lack • GEARBOX
of lubrication in sleeve bearings (metal on metal), 1. GEARMESH FAULTS (PeakVue)
but this is not a well established application. 2. BEARING FAULTS (PeakVue)
8X 9Y 6X 7Y 10 2
TACH
• PUMP ROTOR
IMPELLER
5 4 MOTOR 1
11A
GEARBOX
1. BALANCE
12A 2. ALIGNMENT
3 3. LOOSENESS
THRUST BEARING
FIXED BEARING =
4. BEARING FAULTS

10 POINT COVERAGE 1. OPTIMAL SPEED RANGES
1. MOH – Motor Outboard Horizontal Accelerometer 2. VANE PASS PULSATIONS
2. MIV – Motor Inboard Vertical Accelerometer 3. CAVITATION (PeakVue)
3. MIA – Motor Inboard Axial Accelerometer 4. MOTOR CURRENT DRAW/HP
4. GIH – Gearbox Inboard Horizontal Accelerometer 5. INLET/OUTLET PRESSURE RISE
5. GOH – Gearbox Outboard Horizontal Accelerometer 6. EFFICIENCY
6. PIX – Pump Inboard X axis Eddy Current Sensor 7. SEAL INTEGRITY
7. PIY – Pump Inboard Y axis Eddy Current Sensor 8. RESONANCES
8. POX – Pump Outboard X axis Eddy Current Sensor 9. VENDOR SELECTION
9. POY – Pump Outboard Y axis Eddy Current Sensor
10. Tachometer Tachometer
OPTIONAL (see Note 3):
11. POA – Pump Outboard Axial (thrust) Eddy Current Sensor (Thermo Growth/Thrust)
12. POA – Redundant (Thermo/Thrust) Eddy Current Sensor
Double Suction Pump with Sleeve Bearings
2. The motor has sleeve bearings 1. BALANCE
3. It’s not typical to take a thrust measurement on 2. ALIGNMENT
most pumps or blowers unless they have tight 3. LOOSENESS
internal clearances. Thrust is important on turbo 4. BEARING FAULTS
5. MOTOR FAULTS
FLOW
equipment with tight internal clearances, such as
turbines. 6. COUPLING FAULTS (PeakVue)
4. PeakVue can be used to look at high frequency
sleeve bearing data and could detect low or lack • PUMP ROTOR
of lubrication in sleeve bearings (metal on metal), 1. BALANCE
9 but this is not a well established application. 2. ALIGNMENT
TACH 3. LOOSENESS
8X 9Y 6X 7Y 3X 4Y 1X 2Y 4. BEARING FAULTS
IMPELLER
10A MOTOR • PERFORMANCE (OTHER SENSORS)
11A 1. OPTIMAL SPEED RANGES
THRUST BEARING
FIXED BEARING =
1. MOX – Motor Outboard X axis Eddy Current Sensor 7. SEAL INTEGRITY
2. MOY – Motor Outboard Y axis Eddy Current Sensor 8. RESONANCES
3. MIX – Motor Inboard X axis Eddy Current Sensor 9. VENDOR SELECTION
4. MIY – Motor Inboard Y axis Eddy Current Sensor
5. PIX – Pump Inboard X axis Eddy Current Sensor
6. PIY – Pump Inboard Y axis Eddy Current Sensor
7. POX – Pump Outboard X axis Eddy Current Sensor
9. Tachometer Tachometer
10. POA – Pump Outboard Axial Eddy Current Sensor (Thermo Growth/Thrust)

Boiler Feedwater Pump or Centrifugal Compressor with Sleeve Bearings
2. The motor has sleeve bearings 1. BALANCE
3. The pump will have potential thermo and thrust 2. ALIGNMENT
measurements depending on the vendor 3. LOOSENESS
specified monitoring requirements. 4. BEARING FAULTS
4. PeakVue can be used to look at high frequency 5. MOTOR FAULTS
sleeve bearing data and could detect low or lack 6. COUPLING FAULTS (PeakVue)
FLOW
of lubrication in sleeve bearings (metal on metal),
•
FLOW
but this is not a well established application. PUMP ROTOR
1. BALANCE
9 2. ALIGNMENT
Boiler Feedwater Pump
TACH 3. LOOSENESS
8X 9Y 6X 7Y 3X 4Y 1X 2Y 4. BEARING FAULTS
10A MOTOR • PERFORMANCE (OTHER SENSORS)

11A 1. OPTIMAL SPEED RANGES
THRUST BEARING
FIXED BEARING =
1. MOX – Motor Outboard X axis Eddy Current Sensor 7. SEAL INTEGRITY
2. MOY – Motor Outboard Y axis Eddy Current Sensor 8. RESONANCES
3. MIX – Motor Inboard X axis Eddy Current Sensor 9. VENDOR SELECTION
4. MIY – Motor Inboard Y axis Eddy Current Sensor
5. PIX – Pump Inboard X axis Eddy Current Sensor
6. PIY – Pump Inboard Y axis Eddy Current Sensor
7. POX – Pump Outboard X axis Eddy Current Sensor
9. Tachometer/Key Tachometer
10. POA – Pump Outboard Axial Eddy Current Sensor (Thermo Growth/Thrust)

Vertical Pump with Motor
MECHANICAL FAULTS
• ELECTRIC MOTOR
1 1. BALANCE
2. ALIGNMENT
MOTOR
3. LOOSENESS
5. MOTOR FAULTS
FLOW
3
• PUMP ROTOR
5 1. BALANCE
4 2. ALIGNMENT
3. LOOSENESS
SHAFT
6 RADIAL IF POSSIBLE • PERFORMANCE (OTHER SENSORS)

IMPELLER
4 POINT COVERAGE 4. MOTOR CURRENT DRAW/HP
1. MOH – Motor Outboard Horizontal 5. INLET/OUTLET PRESSURE RISE
3. MIV – Motor Inboard Vertical 6. EFFICIENCY
5. PIV – Pump Inboard Vertical 7. SEAL INTEGRITY
6. POH – Pump Outboard Horizontal 8. RESONANCES
9. VENDOR SELECTION
6 POINT COVERAGE PUMP FOCUSED

MOH – Motor Outboard Horizontal
FLOW
1. 2 POINT COVERAGE
2. MIH – Motor Inboard Horizontal 2. MIH – Motor Inboard Horizontal
3. MIV – Motor Inboard Vertical 5. PIV – Pump Inboard Vertical
4. PIH – Pump Inboard Horizontal
5. PIV – Pump Inboard Vertical SPLIT FOCUS
6. POH – Pump Outboard Horizontal 2 POINT COVERAGE
7. Tachometer (option) 2. MIH – Motor Inboard Horizontal
5. PIV – Pump Inboard Vertical
Paper Machine Rolls
MECHANICAL FAULTS
NON-DRIVEN PAPER MACHINE ROLLS DRIVEN PAPER MACHINE ROLLS
• ELECTRIC MOTOR
Felt Roll Breast Roll
1. BALANCE
Paper Roll Wire Return Roll
2. ALIGNMENT
Forming Roll Couch Roll
Paper Roll 3. LOOSENESS
Calendar Roll
Dryer Can (could be gear driven) 4. BEARING FAULTS (PeakVue)
Dryer Can
5. MOTOR FAULTS
Press Roll
Reel Spool
• GEARBOX
2 2 POINT COVERAGE 1. GEARMESH FAULTS (PeakVue)
NON-DRIVEN ROLL 1. RIA – Roll Inboard Axial 2. BEARING FAULTS (PeakVue)
2. ROH – Roll Outboard Horizontal 3. COUPLING FAULTS (PeakVue)
1
• ROLL
1. BALANCE
2. ALIGNMENT
2 3. LOOSENESS
8 6 5 4 MOTOR 1
DRIVEN ROLL GEARBOX
7 3 1. OPTIMAL SPEED RANGES
3. EFFICIENCY
8 POINT COVERAGE 4. RESONANCES
6 POINT COVERAGE 4 POINT COVERAGE
MOH – Motor Outboard Horizontal 5. VENDOR SELECTION
1. 1. MOH – Motor Outboard Horizontal 3. MIA – Motor Inboard Axial
2. MIV – Motor Inboard Vertical 3. MIA – Motor Inboard Axial 5. GOH – Gearbox Outboard Horizontal
3. MIA – Motor Inboard Axial 4. GIH – Gearbox Inboard Horizontal 7. RIA – Roll Inboard Axial
4. GIH – Gearbox Inboard Horizontal 5. GOH – Gearbox Outboard Horizontal 8. ROH – Roll Outboard Horizontal
5. GOH – Gearbox Outboard Horizontal 7. RIA – Roll Inboard Axial
6. RIH – Roll Inboard Horizontal 8. ROH – Roll Outboard Horizontal 2 POINT COVERAGE
7. RIA – Roll Inboard Axial ROLL FOCUS
8. ROH – Roll Outboard Horizontal 7. RIA – Roll Inboard Axial
9. Tachometer (option) 8. ROH – Roll Outboard Horizontal
Paper Machine Nipped Rolls
MECHANICAL FAULTS
• ELECTRIC MOTOR
The nipped roll’s load zones are in the The press shown has one driven roll and 1. BALANCE
nip direction as shown below. one non-driven roll. It’s possible that 2. ALIGNMENT
both press rolls could be driven and 3. LOOSENESS
would require the same coverage. 4. BEARING FAULTS (PeakVue)
5. MOTOR FAULTS
• GEARBOX
11 1. GEARMESH FAULTS (PeakVue)
11 9
TOP PRESS ROLL
10 2 • ROLLS
1. BALANCE
5 4 MOTOR 1 2. ALIGNMENT
BOTTOM PRESS ROLL GEARBOX
3. LOOSENESS
7 3 4. BEARING FAULTS (PeakVue)
8 8 6
11 POINT COVERAGE 6 POINT COVERAGE 4 POINT COVERAGE 1. OPTIMAL SPEED RANGES
1. MOH – Motor Outboard Horizontal 1. MOH – Motor Outboard Horizontal 3. MIA – Motor Inboard Axial 2. ROLL SURFACE
2. MIV – Motor Inboard Vertical 3. MIA – Motor Inboard Axial 5. GOH – Gearbox Outboard Horizontal PROFILE/RUNOUT
3. MIA – Motor Inboard Axial 4. GIH – Gearbox Inboard Horizontal 6. BIR – Bottom Roll Inboard Radial 3. ECCENTRICITY/RUNOUT
4. GIH – Gearbox Inboard Horizontal 5. GOH – Gearbox Outboard Horizontal 8. BOR – Bottom Roll Outboard Radial 4. MOTOR CURRENT DRAW/HP
5. GOH – Gearbox Outboard Horizontal 6. BIR – Bottom Roll Inboard Radial 5. EFFICIENCY
6. BIR – Bottom Roll Inboard Radial 8. BOR – Bottom Roll Outboard Radial 2 POINT COVERAGE 6. RESONANCES
7. BIA – Bottom Roll Inboard Axial 6. BIR – Bottom Roll Inboard Radial 7. VENDOR SELECTION
8. BOR – Bottom Roll Outboard Radial 8. BOR – Bottom Roll Outboard Radial
Nipped Rolls
9. TIR – Top roll Inboard radial
Wet Press
10. TIA – Top Roll Inboard Axial
Size Press
11. TOR – Top Roll Outboard Radial
Breaker Stack
Calendar Stack
Yankee/Crepe Blade Monitoring
MECHANICAL FAULTS
• ELECTRIC MOTOR (not shown)
1. BALANCE
2. ALIGNMENT
3. LOOSENESS
5. MOTOR FAULTS
• GEARBOX (not shown)

Yankee 1. GEARMESH FAULTS (PeakVue)
• ROLLS
1. BALANCE
2. ALIGNMENT
3. LOOSENESS
Pressure
5. ROLL SURFACE CONDITION
Roll
• YANKEE SHELL THERMAL
Creping DISTORTION
Doctor • YANKEE HEADERS
CREPE BLADE MONITORING • CREPE BLADE
1. CIB – Creping Doctor Inboard 1. WORN BLADE (PeakVue)
Spray
2. COB – Creping Doctor Outboard 2. BAD BLADE (PeakVue)
Boom
3. Yankee Tachometer 3. RESONANCE
ADD YANKEE MONITORING 4. CHATTER (COATING) (PeakVue)
4. YIR – Yankee Inboard Radial
5. YOR – Yankee Outboard Radial •PERFORMANCE
ADD PRESSURE ROLL MONITORING
2. RESONANCES
8. PIR – Pressure Roll Inboard Radial 3. MOTOR CURRENT DRAW/HP
9. POR – Pressure Roll Outboard Radial (requires current sensor)
10. Pressure Roll Tachometer 1. EFFICIENCY
2. VENDOR SELECTION

Paper Machine Screen
MECHANICAL FAULTS
• ELECTRIC MOTOR
1. BALANCE
2. ALIGNMENT
3. LOOSENESS
5. MOTOR FAULTS
6 • V-BELT
1. SHEAVE RUNOUT
2. BELT WHIP
• PUMP ROTOR
1. BALANCE
6 POINT COVERAGE 2. ALIGNMENT
1. MOH – Motor Outboard Horizontal 3. LOOSENESS
2. MIH – Motor Inboard Horizontal 4. BEARING FAULTS (PeakVue)
SHAFT
4. SIH – Screen Inboard Horizontal • PERFORMANCE (OTHER SENSORS)
5. SIA – Screen Inboard Axial 1. OPTIMAL SPEED RANGES
6. SOH – Screen Outboard Horizontal 2. VANE PASS PULSATIONS
1 7. Tachometer (option) 3. CAVITATION (PeakVue)
MOTOR
4 POINT COVERAGE
1. MOH – Motor Outboard Horizontal 6. EFFICIENCY
4 3. MIA – Motor Inboard Axial 7. RESONANCES
5. SIA – Screen Inboard Axial 8. RUSH/DRAG RATIO
5 2
6. SOH – Screen Outboard Horizontal 9. VENDOR SELECTION
3
Many screens have v-belt drives and 2 POINT COVERAGE

variable speed motor combinations. SCREEN FOCUS
1. SIA – Screen Inboard Axial
6. SOH – Screen Outboard Horizontal
Wood Chipper, Disk Style with Gearbox and Motor
MECHANICAL FAULTS
• ELECTRIC MOTOR
1. BALANCE
2. ALIGNMENT
3. LOOSENESS
5. MOTOR FAULTS
10 TACHOMETER
• GEARBOX
ROTOR
8 6
5 4 MOTOR 1 • CHIPPER ROTOR
SHAFT GEARBOX 1. BALANCE
2. ALIGNMENT
7 3
3. LOOSENESS
9
LOG
• PERFORMANCE (WITH
TACHOMETER AND OTHER SENSORS)
2. BLADE PASS FREQUENCY
ONLINE COVERAGE
4. EFFICIENCY
1. MOH – Motor Outboard Horizontal
5. ROTOR STALL
2. MIV – Motor Inboard Vertical
6. RESONANCES
7. VENDOR SELECTION
4. GIH – Gearbox Inboard Horizontal
5. GOH – Gearbox Outboard Horizontal
6. CIH – Chipper Inboard Horizontal
7. CIA – Chipper Inboard Axial
8. COH – Chipper Outboard Horizontal
9. MOTOR CURRENT
10. TACHOMETER
Conveyor Drive
MECHANICAL FAULTS
• ELECTRIC MOTOR
Online monitoring the conveyor 1. BALANCE
drive systems (there could be 9 11
2. ALIGNMENT
more than one) is where the 3. LOOSENESS
biggest ROI can be found on 4. BEARING FAULTS (PeakVue)
overland conveyors. Changing 5. MOTOR FAULTS
the damaged drive during a 10
scheduled downtime instead of
during an unscheduled down • GEARBOX
time is a huge ROI. 1. GEARMESH FAULTS (PeakVue)
1 MOTOR 4 5
GEARBOX • ROLL
1. BALANCE
3 7
6 8 2. ALIGNMENT
3. LOOSENESS
1. MOH – Motor Outboard Horizontal 1. MOH – Motor Outboard Horizontal 3. MIA – Motor Inboard Axial • PERFORMANCE (OTHER SENSORS)
2. MIV – Motor Inboard Vertical 3. MIA – Motor Inboard Axial 5. GOH – Gearbox Outboard Horizontal 1. OPTIMAL SPEED RANGES
3. MIA – Motor Inboard Axial 4. GIH – Gearbox Inboard Horizontal 6. BIR – Bottom Roll Inboard Radial 2. MOTOR CURRENT DRAW/HP
4. GIH – Gearbox Inboard Horizontal 5. GOH – Gearbox Outboard Horizontal 8. BOR – Bottom Roll Outboard Radial 3. EFFICIENCY
5. GOH – Gearbox Outboard Horizontal 6. BIR – Bottom Roll Inboard Radial 4. RESONANCES
6. BIR – Bottom Roll Inboard Radial 8. BOR – Bottom Roll Outboard Radial 2 POINT COVERAGE 5. VENDOR SELECTION
7. BIA – Bottom Roll Inboard Axial 6. BIR – Bottom Roll Inboard Radial
8. BOR – Bottom Roll Outboard Radial 8. BOR – Bottom Roll Outboard Radial
9. TIR – Top roll Inboard radial
10. TIA – Top Roll Inboard Axial
11. TOR – Top Roll Outboard Radial Conveyor belt idler rolls are not typically ever
12. Tachometer (option) online vibration monitored. These idler roll
bearings would be checked using infrared or
ultrasonics because there are so many of these
on a typical conveyor. Infrared is the most
Emerson proprietary information practical technology to use.
MENU
Electric Rope Shovel
M3R M1R MNR MECHANICAL FAULTS
• ELECTRIC MOTOR
1. BALANCE
M4R
D1R D1A
M2R 2. ALIGNMENT
M4A I3R I1A
M2A
I3A I1R
MDR IUR 3. LOOSENESS
P3R P1R
GEARBOX
PUR
ILR
GEARBOX
P4R P2R
PLR 5. MOTOR FAULTS
P4A P2A 6. COUPLING FAULTS (PeakVue)
I4R I2R
HOIST DRUM
OUR
• GEARBOX
OLR 1. GEARMESH FAULTS (PeakVue)
Swing 2 Zones 3. COUPLING FAULTS (PeakVue)
D2R
• DRIVEN ELEMENT
Hoist 2 zones 1. Crowd System: the crowd system is an electric motor and gearbox system driving a rack and pinion
1. BALANCE
2. ALIGNMENT
gear system to pull the bucket toward and away from the shovel.
3. LOOSENESS
2. Hoist System: the hoist system has electric motors driving a gearbox that turns a drum that rolls up 4. BEARING FAULTS (PeakVue)
the cable that lifts and lowers the bucket
4. PROPEL SYSTEM 3. Swing System: the swing system uses multiple electric motors to drive gearboxes that turn a bull • PERFORMANCE (OTHER SENSORS)
gear that turns the cab and boom to the left or to the right. 1. OPTIMAL SPEED RANGES
INTERMITTENT
4. Propel System: the electric rope shovel tracks use traction converters to turn the sprockets that 2. MOTOR CURRENT DRAW/HP
PROPEL
drive the tracks. The left and right side tracks are independently driven. 3. EFFICIENCY
1. CROWD SYSTEM
4. RESONANCES
5. VENDOR SELECTION
7–10 Seconds
HOIST ILA
MNR PLR ILR
SWING CROWD
GEARBOX
2. HOIST SYSTEM
MDR
MDA
8–10 Seconds PCR PCA ICR
PROPEL
Emerson proprietary information

Crowd 1 Zone MENU
14
13 12
SAG Mill Applications
SAG or BALL MILL

• Load change – for more effective DRIVE
MECHANICAL FAULTS
• ELECTRIC MOTOR
TOP of
liberation of the mineral, and 1. MOH – Motor Outboard Horizontal
1. BALANCE
more energy effective size 2. MIV – Motor Inboard Vertical
2. ALIGNMENT
reduction. 3. LOOSENESS
4. GIH – Gearbox Inboard Horizontal 7B 7A 4. BEARING FAULTS (PeakVue)
• Pooling within the mill - will run 5. GOH – Gearbox Outboard Horizontal
5. MOTOR FAULTS
more efficiently (energy efficient) MILL PINION
6. PIR – Pinion Inboard Radial 8 TACHOMETER
and minimize water use (reduced 7. POR – Pinion Outboard Radial 6B 6A
10 •
impact on plant water balance) MILL
9 GEARBOX
• Ball addition can be optimised 8. Mill Tachometer 11 2. BEARING FAULTS (PeakVue)
9. SIH – SAG Inboard Horizontal
• Liner and lifter performance can 10. SIV – SAG Inboard Vertical 5B 5A
GEARBOX
GEARBOX
be inferred. 11. SIA – SAG Inboard Axial
• MILL
12. SIH – SAG Outboard Horizontal 4B 4A 1. RUNOUT
13. SIV – SAG Outboard Vertical
2. LOAD SHIFT (Phase with Tach)
14. SIA – SAG Outboard Axial 2B 3B 2A 3A
3. ALIGNMENT
4. LOOSENESS
MOTOR
MOTOR
6. BULL GEAR FAULTS (PeakVue)
1B 1A
7. PINION GEAR FAULTS (PeakVue)
BULL GEAR
SAG MILL 2. MOTOR CURRENT DRAW/HP
3. EFFICIENCY
4. RESONANCES
BRG 9 8 TACHOMETER 5. VENDOR SELECTION
11
10
PINION PINION
6A 6A
MENU
Steam Turbine Monitoring

Combustion Turbine Monitoring
• The combustion turbine vendor should specify where to mount all protection 1- Air Inlet
monitoring measurements 2- Compressor Section
3- Combustor Section
• Below is a possible sensor arrangement: 4- Turbine Section
18 POINT COVERAGE SLEEVE BEARING ANTIFRICTION BEARING 5- Exhaust Housing
1. C1X – COMP Outboard X axis Eddy Current Sensor or ACCELEROMETER
MECHANICAL FAULTS
2. C2Y – COMP Outboard Y axis Eddy Current Sensor or ACCELEROMETER
• TURBINE / GENERATOR
3. C3X – COMP Inboard X axis HIGH TEMP ACCELEROMETER
1. BALANCE
4. C4Y – COMP Inboard Y axis HIGH TEMP ACCELEROMETER
2. ALIGNMENT / RUNOUT
5. T5X – LP Inboard X axis Eddy Current Sensor or ACCELEROMETER
3. LOOSENESS
6. T6Y – LP Inboard Y axis Eddy Current Sensor or ACCELEROMETER
4. SPEED
7. G7X – Generator Inboard X axis Eddy Current Sensor
5. RESONANCES
8. G8Y – Generator Inboard Y axis Eddy Current Sensor
6. SHAFT CRACK (1X AMP/PHASE)
9. G9X – Generator Outboard X axis Eddy Current Sensor
7. RUBS (PeakVue)
10. G10Y – Generator Outboard X axis Eddy Current Sensor
8. VANE PASS
11A. 11A – Redundant (Thermo/Thrust) Eddy Current Sensor
9. CASE VIBRATION
11B. 11B – Redundant (Thermo/Thrust) Eddy Current Sensor
10. THRUST
11C. 11C – Redundant (Thermo/Thrust) Eddy Current Sensor
11. EXPANSION
12. COMP Speed/Key Tachometer Eddy Current Sensor or Hall Effect Sensor
• SLEEVE
13. TURBINE Speed/Key Tachometer Eddy Current Sensor or Hall Effect Sensor
11. ORBIT
14. Inlet Dynamic Pressure Dynamic Pressure Sensor
12. OIL FILM STABILITY (PeakVue)
15. Case Vibration High Temp Accelerometer
13. SHAFT CENTER LINE (SCL)
16. Case Vibration High Temp Accelerometer
• ANTIFRICTION
12 KEY/SPEED
16 13
BRG 2
EXHAUST KEY/SPEED
INLET
15
1X 2Y 5X 6Y 7X 8Y 9X 10Y
14 3X 4Y
COMPRESSOR TURBINE GENERATOR
11
THRUST
BRG 4
BRG 1
BRG 3
BRG 5
COMBUSTION
CHAMBER
CASE
CASE
MENU
Hydro Power
MECHANICAL FAULTS
1 • HYDRO TURBINE GENERATOR
3 2 GENERATOR BEARING 1. BALANCE
4 2. ALIGNMENT
3. LOOSENESS
5 4. SPEED
5. OVERSPEED
6
6. RESONANCES
7 7. SHAFT CRACK (1X AMP/PHASE)
8 8. RUBS (PeakVue)
9. VANE PASS
10. CASE VIBRATION
9 11. THRUST
12. EXPANSION
10 TACHOMETER/KEY 13. SHAFT ORBIT
GENERATOR OUTBOARD 14. BEARING OIL FILM STABILITY (PeakVue)
1. GOA – Generator Outboard Axial Accel/Velocity 11 15. SHAFT CENTER LINE (SCL)
2. GBR – Generator Bearing Radial Accel/Velocity 16. AIR GAP / RUNOUT
3. GSR – Generator Shaft Radial Eddy Current 17. PARTIAL DISCHARGE
12
4. GOT – Generator Bearing Temperature RTD/Thermocouple 18. TEMPERATURE
GENERATOR STATOR and GAPS
5. GSR – Generator Stator Radial (Absolute) Accel/Velocity
6. GPD – Generator Partial Discharge (multiple) Partial Discharge
7. GAG – Generator Air Gap (multiple) Air Gap 14 13 TURBINE BEARING
15
8. GGT – Generator Gap Temperature (multiple) RTD/Thermocouple 16 17
GENERATOR INBOARD
9. GIT – Generator Inboard Thrust Eddy Current
10. KEY – Speed and Phase reference Hall/Eddy Current
11. DOPS – Overspeed (triple redundant) Hall/Eddy Current
12. SRR – Eccentricity (shaft runout radial) Eddy Current
TURBINE INBOARD
13. TSR – Turbine Bearing Radial Accel/Velocity
14. TBR – Turbine Shaft Radial Eddy Current
15. TBT – Turbine Bearing Temperature RTD/Thermocouple
16. HIV – Head Cover Inboard Vertical Accel/Velocity
17. VIV – Vane Inboard Vertical Accel/Velocity
MENU
Package Compressor
A small package compressor platform with

single eddy current sensors radially, vertically
The compressors motor and gearbox nay
mounted to measure vibration at top dead
have antifriction bearings which would use
center on each stage’s sleeve bearings
accelerometers and PeakVue for monitoring
CONTROL
SYSTEM DISPLAY
CONTROL
GEARBOX
STAGE 2
4-20 mA
LOOP
STAGE 1
PACKAGE COMPRESSOR
TRANSMITTER

Recips 9
8 TACHOMETER
MECHANICAL FAULTS
• DRIVE
PISTON
RIDER BANDS 1. BALANCE
10
2. ALIGNMENT
A recip drive can be a natural gas 3. LOOSENESS
powered piston engine, a small 13 4. BEARING FAULTS (PeakVue)
ROD
steam turbine or an electric 12 13 5. MOTOR FAULTS
ROD FLEX ROD DROP
motor. Drive arrangements can 6. COUPLING FAULTS (PeakVue)
include a gearbox as shown or
•
CROSSHEAD
be direct driven. 11 GEARBOX
6 1. GEARMESH FAULTS (PeakVue)
FLYWHEEL
1 MOTOR 4 5
GEARBOX
TOP SHAFT • RECIP
3 1. BALANCE
2. ALIGNMENT
3. LOOSENESS
DRIVE
1. MOH – Motor Outboard Horizontal Accelerometer 5. VALVE FAULTS (PeakVue)
2. MIV – Motor Inboard Vertical Accelerometer 6. ROD FLEX
3. MIA – Motor Inboard Axial 7. ROD DROP
GEARBOX 8. CROSSHEAD LOOSENESS
4. GIH – Gearbox Inboard Horizontal Accelerometer 9. PISTON LOOSENESS
5. GOH – Gearbox Outboard Horizontal Accelerometer
COMPRESSOR BODY • PERFORMANCE
6. CIH – Compressor Inboard Horizontal Accelerometer 1. PV Curves (pressure sensor)
7. COH – Compressor Outboard Horizontal Accelerometer 2. OPTIMAL SPEED RANGES
8. KEY/SPEED Tachometer 3. MOTOR CURRENT DRAW/HP
4 THROWs (a throw is a cylinder) 4. EFFICIENCY
9. 4x TVA – Throw Valve Axial Accelerometer 5. RESONANCES
10. 4x TVR – Throw Valve Radial Accelerometer 6. VENDOR SELECTION
11. 4x CHV – Crosshead Vertical Accelerometer
12. 4x RFH – Rod Flex Horizontal Eddy Current Sensor
4x RDV – Rod Drop Vertical
13. Eddy Current Sensor
Wind Turbine
MECHANICAL FAULTS
• MAIN BEARING
1. BALANCE
2. ALIGNMENT
3. LOOSENESS
4. RESONANCES
9 TACHOMETER
• GEARBOX
GEARBOX 12 3. COUPLING FAULTS (PeakVue)
11
5 6 • GENERATOR
GENERATOR
MAIN BEARING 1. BALANCE
10
7 8 1. MOH – MB Outboard Horizontal 2. ALIGNMENT
GEARBOX 3. LOOSENESS
BLADE
3 4 2. G1A – Gearbox Bearing 1 Vertical

MAIN BEARING

3. G1V – Gearbox Bearing 1 Axial/Radial 5. GENERATOR FAULTS
5 6 4. G2A – Gearbox Bearing 2 Axial/Radial
5. G3A – Gearbox Bearing 3 Axial/Radial • PERFORMANCE
6. G4A – Gearbox Bearing 4 Axial/Radial 1. SPEED / WIND SPEED
2
1 2 TOP VIEW 7. G5A – Gearbox Bearing 5 Axial/Radial 2. RESONANCES
HUB
8. G6A – Gearbox Bearing 6 Axial/Radial 3. VENDOR SELECTION
3 4 GENERATOR
1 9. Tachometer • OTHER APPLICATIONS
10. GIA – Generator Inboard Axial 1. BLADE STRESS (PeakVue)
BLADE
11. GIV – Generator Inboard Vertical 2. TURRENT BEARING (PeakVue)

12. GOH – Generator Outboard Horizontal 3. TEMPERATURE
4. OIL MONITORING
5. TOWER SWAY
SUN GEAR
How to online monitor typical assets
Details of typical assets, sensor placement and
expected applications
MENU
BOP Asset Online Vibration Monitoring Design
• This document is intended to show detailed MHM vibration monitoring schemes for common BOP
assets such as:
FLOW
– Cooling Tower Fans
– SISW Blowers (Single Sided Single Width Fan)
– DIDW Blowers (Double Sided Double Width Fan)
– Single Suction Pumps
– Double Suction Pumps
– Vertical Pumps
– Turbines
– and many more …
• This document is also intended to show what these assets generally look like so that the
monitoring points are recognizable.
• The goal of online monitoring is not to collect every available point on an asset, but to capture a
relevant set of points so that, at the least, the basic asset health can be determined
MENU
BOP Asset Online Vibration Monitoring Design
• When monitoring a point on an asset, there has to be a goal of what data is
expected:
• For Prediction:
– If just an antifriction bearing status is needed then usually an axial measurement near
the bearing load zone is needed for a good PeakVue reading.
– If antifriction bearing data is required but there is also a need to evaluate balance and
alignment then a radial measurement should be taken. Generally a horizontal radial
measurement is better than a vertical radial measurement since the vertical
measurement is gravity loaded.
– When there are several points available to monitor an asset, the point distribution
should be designed to allow some horizontal, vertical and axial inputs to get a good
overall idea of both the asset’s components health and the asset’s general movement
• The pages in this document show suggested designs for monitoring assets.
In many cases the actual coverage will have to be different from these
suggestions because of inaccessibility or an actual vibration survey of
points to determine the best locations to collect data.
MENU
BOP online vibration monitoring; Assets
• The three most common BOP assets are:
– Pumps
– Centrifugal Fans
– Cooling Tower Fans
PUMP
FAN
COOLING TOWER FAN
MENU
There are two bearing types
• Antifriction Bearings • Sleeve Bearings
• Most common BOP bearing – Sensor equal eddy current sensor
– Sensor equal accelerometer – Faults
– Faults • Thrust (axially mounted eddy current sensors)
• Cage/Train frequency • Orbit
• Ball spin frequency • Radial position (SCL – shaft centerline)
• Outer race frequency • Oil whip
• Inner race frequency
XY Orbit
ANTI-FRICTION BEARING SLEEVE BEARING
MENU
Placing sensors on an asset
• Assuming a fixed speed and antifriction bearings; this simple pump requires 6 accelerometers for
full online monitoring
– The yellow block indicates the many faults that the online vibration system can track
• For a variable speed pump, a tachometer should be added for accurate fault calculations
MECHANICAL FAULTS
FLOW
• ELECTRIC MOTOR
1. BALANCE
2. ALIGNMENT
3. LOOSENESS
5. MOTOR FAULTS
TACH
2 • PUMP ROTOR
1. BALANCE
6 4 2. ALIGNMENT
IMPELLER
MOTOR 1 3. LOOSENESS
FLOW SHAFT 4. BEARING FAULTS (PeakVue)
5 • PERFORMANCE (OTHER SENSORS)

3 1. OPTIMAL SPEED RANGES
6 POINT COVERAGE 3. CAVITATION (PeakVue)
1. MOH – Motor Outboard Horizontal 4. MOTOR CURRENT DRAW/HP
2. MIV – Motor Inboard Vertical 5. INLET/OUTLET PRESSURE RISE
3. MIA – Motor Inboard Axial 6. EFFICIENCY
4. PIH – Pump Inboard Horizontal 7. SEAL INTEGRITY
5. PIA – Pump Inboard Axial 8. RESONANCES
6. POH – Pump Outboard Horizontal 9. VENDOR SELECTION
7. Tachometer (optional)
MENU
Wiring the system together: Sensors
• Sensor wiring to the system:
– Accelerometers are typically powered by the online system
– Eddy current sensors require a converter; the converter is typically powered by the system
– Both may require a junction box for supporting field cable splices and converters (for the eddy current sensors)
ACCELEROMETER
FIELD SPLICE
IF NEEDED
SENSOR FIELD CABLE
CABLE SUPPLIED BY CUSTOMER
JUNCTION
BOX
IF NEEDED
SENSOR EXTENSION FIELD CABLE
CABLE OR CABLE SUPPLIED BY CUSTOMER
EDDY CURRENT
SENSOR
IF ORDERED
ADAPTOR
PIGTAIL
CONVERTER
MENU
Wiring the system together: Network
• System to the server:
– Online systems are typically Ethernet connected to the server
– Its best if the online system has a dedicated LAN
• One online system cabinet can monitor several assets
ETERNET
TO ONLINE SERVER
MENU
Online Project Commissioning
• Commissioning
– A system can be commissioned when the following has been completed:
• Sensors are mounted on the asset and wired either directly to a online vibration monitoring system or they are
wired to a junction box which is wired to a online vibration monitoring systems.
• The online vibration monitoring system is installed and ready for sensor termination.
• The online vibration monitoring system is connected via network to a server running the online vibration
monitoring system software.
• Commissioning will consist of the following:
– Terminating and testing the sensor connections to the online vibration monitoring system
– Testing the connection between the online vibration monitoring system and the online vibration monitoring
software on the server
– Creating and testing the online vibration monitoring measurement channels
– Once the system is running correctly; turning the system over to the customer.
MENU
Summary
• A well designed online prediction monitoring system will:
– Provide reliable and constant feedback on the health of assets and processes and the effect of process changes
– Allow the identification of best operating parameters
– Reduce or eliminate unplanned outages, reducing maintenance budgets
– Help provide a safer workplace
MENU

Howto Online Monitor Typical Assets

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Steam Paper Paper Mining

• PERFORMANCE (OTHER SENSORS)

6 POINT COVERAGE 4 POINT COVERAGE 2 POINT COVERAGE

6 POINT COVERAGE 4 POINT COVERAGE 2 POINT COVERAGE

DIDW – Double Inlet Double Width • GEARBOX

8 6 5 4 MOTOR 1 • FAN ROTOR

• PERFORMANCE (OTHER SENSORS)

6 POINT COVERAGE 4 POINT COVERAGE FAN FOCUS

6. COUPLING FAULTS (PeakVue)

• PERFORMANCE (OTHER SENSORS)

5 3 • PERFORMANCE (OTHER SENSORS)

Emerson proprietary information MENU

• PERFORMANCE (OTHER SENSORS)

Emerson proprietary information MENU

5 3 • PERFORMANCE (OTHER SENSORS)

Emerson proprietary information MENU

• PERFORMANCE (OTHER SENSORS)

Emerson proprietary information MENU

10A MOTOR • PERFORMANCE (OTHER SENSORS)

Emerson proprietary information MENU

6 RADIAL IF POSSIBLE • PERFORMANCE (OTHER SENSORS)

6 POINT COVERAGE PUMP FOCUSED

• GEARBOX (not shown)

Emerson proprietary information MENU

Many screens have v-belt drives and 2 POINT COVERAGE

Emerson proprietary information

SAG Mill Applications

SAG or BALL MILL

Emerson proprietary information MENU

A small package compressor platform with

Emerson proprietary information MENU

3 4 2. G1A – Gearbox Bearing 1 Vertical

4. BEARING FAULTS (PeakVue)

11. GIV – Generator Inboard Vertical 2. TURRENT BEARING (PeakVue)

COOLING TOWER FAN

ANTI-FRICTION BEARING SLEEVE BEARING

5 • PERFORMANCE (OTHER SENSORS)

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