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Guide for the Application of Condition Based Maintenance within the Planned Maintenance Scheme
INDEX
General ..................................................................................................................................................2
3.2
Vibration Monitoring...............................................................................................................................2
3.2.1
3.2.2
3.2.3
3.2.4
3.2.5
3.2.6
3.2.7
3.2.8
3.2.9
3.2.10
3.2.11
3.2.12
Introduction.............................................................................................................................2
Vibration Parameters..............................................................................................................2
Vibration Measurements ........................................................................................................2
Standardisation of the measurement .....................................................................................3
Calibration ..............................................................................................................................3
Baseline Measurements.........................................................................................................3
Vibration Analysis...................................................................................................................3
Broadband vibration ...............................................................................................................3
Frequency Spectrum Analysis ...............................................................................................5
Typical interpretations of the causes of vibration at specific frequencies ..............................6
Minimum Technical Characteristics of the Measurement Instrumentation ............................8
Minimum Frequency of Measurements..................................................................................8
3.3
3.4
Guide for the Application of Condition Based Maintenance within the Planned Maintenance Scheme
vibration monitoring
thermography.
THEORY
UNDERLYING
DETERMINATION
OF
CBM
INTERVALS
THE
TASK
Figure 1
Guide for the Application of Condition Based Maintenance within the Planned Maintenance Scheme
3.1
General
For
consistent
and
comparable
results,
measurements should always be taken under
operating conditions that are as close as possible to
those that may be considered as normal for the
machine (baseline conditions), including sea and
weather conditions.
Vibration Monitoring
3.2.1 Introduction
Wear
Imbalance
Misalignment
Looseness
Bearing damage
Resonance
Fatigue
Deformation of a shaft
Cavitation.
Guide for the Application of Condition Based Maintenance within the Planned Maintenance Scheme
3.2.5 Calibration
Repeatable
and
accurate
vibration
measurements on stationary parts require
adequate contact between the transducer and
the vibrating surface. Fixed transducers may be
mechanically connected or bound to the machine
in such a way as to avoid unreliable measures
caused by undue stress or motion. If portable
systems are employed, it is to be ensured that a
positive means of contact is used.
The most common types of transducers used for
vibration monitoring are:
a) Accelerometers, the outputs of which can be
processed to give any of the three vibration
parameters - acceleration, velocity or
displacement.
Guide for the Application of Condition Based Maintenance within the Planned Maintenance Scheme
Medium Machinery
Large Machinery
< 15 kW
15 - 75 kW
> 75 kW
Rigid foundations
Flexible foundations
Good
0,7
1,1
1,8
2,8
Satisfactory
1,8
2,8
4,5
7,1
Unsatisfactory
4,5
7,1
11,2
18,0
> 4,5
> 7,1
> 11,2
> 18,0
Excessive
Guide for the Application of Condition Based Maintenance within the Planned Maintenance Scheme
Guide for the Application of Condition Based Maintenance within the Planned Maintenance Scheme
3.2.10
a) Imbalance
In all machines. Imbalance, due e.g. to soft
foot. A line at 1X, the fundamental
frequency, is generally present in the
spectrum of rotating machines. It occurs
predominantly in radial directions.
The amplitude is significant.
Figure 4
e) Gear damage
In gear boxes. Look for 3 sidebands of the
gear mesh frequency (GMF), modulation
with the rpm of this shaft, plus 4 harmonics.
The GMF itself is usually present. The
appearance of sidebands (and harmonics)
shows damage.
Input number of teeth of driving wheel.
b) Misalignment
In all machines with couplings, belt drive.
High values in axial direction. In general, two
types of misalignment exist, namely:
- parallel misalignment, which is revealed
by high values in radial directions
- angular misalignment, which is revealed
by high values in axial direction.
Vibrations due to eccentricity have similar
characteristics to those due to imbalance
and misalignment.
Figure 8
Figure 5
f)
Gear alignment
In gearboxes. Look for 1st to 3rd harmonic
of GMF (2nd and 3rd should be higher than
1*GMF), with 1 sideband, modulation with
the rpm of the shaft.
Input number of teeth of driving wheel.
Figure 9
Guide for the Application of Condition Based Maintenance within the Planned Maintenance Scheme
g) Gear assembly
In gearboxes. Look for the GAPF (gear
assembly phase frequency), which is a
fraction of GMF.
Input the assembly phase factor NA.
Figure 10
Figure 11
i)
Eccentric stator, 50 Hz
In electric motors. Look for the double line
frequency.
This
line
is
due
to
magnetostriction, always present, with
normal amplitudes depending on motor
design. Increased amplitudes can be due to
an uneven stationary air gap between rotor
and stator. Can even be a sign of soft foot, a
warped base, loose iron, or shorted stator
laminations.
Figure 12
Figure 14
l) Belt problems
In belt transmissions. Look for the 1X to 4X
modulated with the belt frequency (BPF), 3
sidebands.
j)
Figure 15
Rotor faults, 50 Hz
In electric motors. Look for 1X and 5
harmonics with 2 sidebands, modulation
with the pole pass frequency, which is the
slip frequency multiplied by the number of
poles.
Guide for the Application of Condition Based Maintenance within the Planned Maintenance Scheme
m) Oil whirl
In journal bearings. Look for oil whirl
frequency, 0,42 to 0,48X.
Figure 16
3.3
where:
FTF = Fundamental Train Frequency
BSF =Ball Spin Frequency
BPFO =Ball Pass Frequency Outer race
BPFI = Ball Pass Frequency Inner race
FTF
1.
2
d.
cos
D
BSF
D .
1
2. d
BPFO
N . FTF
BPFI
N . ( Rps
. Rps
d.
cos
D
. Rps
FTF )
Parameter
Viscosity
Flashpoint
Water concentration
Alkalinity
Strong acid
Acidity
Insoluble substances
Metals
Microbial concentration
Particle count
Condition to detect
Increase or decrease
Decrease
Presence of salt or fresh water
Increase or decrease
Presence
Increase
Increase
Increase
104
Increase
Guide for the Application of Condition Based Maintenance within the Planned Maintenance Scheme
total mass
particle rate
alarm indications
Figure 18
Figure 20
Guide for the Application of Condition Based Maintenance within the Planned Maintenance Scheme
Figure 21
3.4
of
REMARKS
1C T 10C
20C < T 30 C
Above 30C
10