1

Predicting Machine Failure

This presentation introduces predictive maintenance technologies and their use to

improve the bottom line of manufacturing operations.

Agenda:
Introduction to maintenance and asset management
Machinery Monitoring and Diagnostics
Machinery Vibration System
Data Acquisition and Signal Conditioning
Signal Processing
Technical Data Management
Example Real-World Installations
Architectural Summary
Conclusions

2
 The Economics of Maintenance
Globalization of economies
Pressure to reduce manufacturing costs
Higher volume markets (machine uptime)
Geographic specific factors
Aging workforce and equipment
Reductions in capital investment for newer machinery
Increased machinery automation technologies
Programmable Automation Controllers

With the globalization of our world economy, competition for our customers
exists from every reach of the globe. As a manufacturing company, we are
able to reduce the cost of our products in part by improving the reliability of
our manufacturing machinery. Further, with a world wide market, we can
produce products in higher volumes. Higher volumes in turn imply higher
utilization and uptime of our machinery.

In the USA, manufacturing suffers from an aging workforce and from aging
equipment relative to newly mobilizing economies. Cost pressures are even
higher in the USA as newly emerging economies introduce a competitive cost
structure. As our corporations debate adding manufacturing operations
overseas, we delay capital investment in newer machinery.

Fortunately, the world economy competitive forces and demands have

increased the capabilities of off the shelf control and monitoring equipment,
while driving down the cost. As manufacturers, we can leverage these new
technologies to improve the competitive posture of our manufacturing
operations by reducing maintenance costs and improving machinery
reliability.

3
 Benefits of Intelligent Maintenance Systems
(Asset Management)
Reduce scrap and raw material consumption
Lowers Cost of Raw Materials
Reduce downtime
Increases Output and Revenue
Lengthen maintenance cycle
Lowers cost of maintenance and service

By improving the reliability of our machinery, there are several economic

benefits we can accrue.

As machinery runs more smoothly and reliably, we have less waste of raw
materials. Often times this comes from the prevention of machinery failure in
the middle of a production run. In addition, vibrations from unhealthy
machinery can actually impact product quality as well. For example, in rolling
mill applications such as paper and steel, bearing vibrations on rollers can
create chatter on the rollers thus leaving a washboard like imprint on the end
product.

With an intelligent machine failure prediction tool, manufacturing schedules

and maintenance schedules can be optimized for product flow, people
resources, and even spare parts inventory. It is this optimization process that
often yields the largest financial gain with machinery vibration solutions.

Finally, scheduling maintenance when it is needed, rather than on a machine

manufacturers suggested schedule can lengthen the time a machine is in
service between maintenance outages.

4
 Asset Management
Sensors
Is the sensor working (bias voltage)
Calibration information and health
Machinery
Scrap rates, energy consumption
Mechanical Health (gears, bearings, etc.)
Control Systems
PID loop tuning
I/O Functionality Health

Considering machinery is a critical manufacturing asset, we can look at

machinery reliability as a key component in an asset management system.

Asset Management does include other aspects of a manufacturing

environment. Sensors such as valves, temperature transmitters, flow
transmitters, and so on; are also key assets in a process plant. Often, sensor
asset management is provided within the realm of the intelligent sensor.
IEEE-1451 (TEDS), Foundation Fieldbus, Hart, and other intelligent sensing
technologies give us tools for tracking and managing the health of the
sensors and their networks.

On the other end, the control systems contain both analog and digital inputs
and outputs (I/O) as well as control logic. The I/O calibration information, and
operational status is another element of asset management in a production
environment. Further, with changing suppliers of raw materials, control
systems may need to be re-tuned. An out of tune process creates waste in
raw materials, and can even damage or increase wear rates on machinery.

Machinery is often the largest capital expense in a plant. Operation

parameters indicating performance and energy consumption are good
indicators of a machines health. The mechanical health of the machine can
further be measured with vibration analysis.

5
 What is a Maintenance System?
Service Personnel
Spare Parts Inventory
Machinery Monitoring and Diagnostics
THE DATA
Computerized Maintenance Management Systems

Within the asset management framework lies a maintenance system.

A maintenance system includes service personnel, spare parts inventory,

machinery diagnostic information, and a computerized system for tracking
maintenance information.

Personnel, spare parts inventory, and corrective actions are all driven by
data. This data is collected from machinery, and in particular from machinery
monitoring and diagnostics hardware and software applications.

6
 Machinery Monitoring and Diagnostics
Electrical Power
Machinery Vibration
Thermography
Tribology
Operational Monitoring

Looking at the broader scope of machinery monitoring and diagnostics

applications areas, there are several sources of machinery health and reliability
indicators.

Electrical power measurements provide both power consumption trends, and

electrical power signatures. The electrical power signatures can be dissected with
signal processing tools to determine the health of electric motors and motor
control systems.
Thermography is the tool for collecting temperatures from key machinery
components. Thermography includes both temperature sensing devices on
machines such as RTDs in motor windings, on bearing housings, and on
compressor cylinder heads. Thermography also includes thermal imaging for
tracking temperature changes in electrical motor control panels and electrical
distribution within the plant.
Tribology is oil analysis. Oil is the lifeblood of most machinery. Oil viscosity,
cleanliness, and even particle analysis plays a role in machinery maintenance
systems.
Operational Monitoring is simply a review of all the machinery parameters that are
part of the control system and the operator interactions with the machine.

The most common machinery monitoring and diagnostics tool, is machinery

vibration applications. Machinery vibration systems are discussed in more detail
next.

7
 Machine Condition Monitor System Elements
Software
Application
Development Tools
Development
Sound and Vibration,
Signal Sources/ Environment
Order analysis,
LabVIEW, C/C++,
Signal processing
Unit Under Test LabWindows/CVI, etc.
Acoustics, Sound,
Vibration, Audio

Computer
PCI or PXI-based
Hardware
Transducers
Simultaneous
Accelerometers,
Acquisition/DSA
Proximity Probes,
NI 4472, NI4451,
Tachometers,
SCXI, SCC
Pressure probes

Taking a closer look at Machinery Vibration Diagnostics and Machinery

Condition Monitoring Systems, we find the following components.
The first component is the machine you intend to monitor.
Transducers such as accelerometers, proximity probes, and
thermocouples convert machine-generated signals such as sound,
vibration, temperature, pressure, power consumption, and others
into a measurable voltage.
Cabling and perhaps signal conditioning hardware connect your
transducers to a measurement instrument.
The measurement instrument here is a standard PC. As well see,
this offers a number of benefits. For now though, lets focus on the
overall system.
Installed hardware and software converts the PC into a
measurement instrument.
Acquisition hardware in the form of plug-in PCI or
CompactPCI/PXI card or cards can provide signal conditioning and
converts the sensor output to a computer-friendly format.
Software for measurement and automation controls our acquisition
hardware, provides a monitor-site man/machine interface (MMI),
and interprets acquired signals for monitoring, and assists in
diagnosis. Software can also provide functions such as signal
interpretation, report generation, and data sharing.

8
 Vibration Sources
Loose Mechanical Unbalance
Components Bent Shaft Blade Pass /
Gears Fluid Related
Slot Frequency /
EM related
Alignment

Motor
Journal (Fluid Film)
Bearings
Mechanical Rolling Element
Resonances Couplings
Bearings

While the computer-based machinery monitoring system is capable of

monitoring many sensors and signals, we will focus on vibration for the
majority of this presentation.

Lets consider some vibration sources of a generic operating machine.

Some vibration sources are due to machine design: slot frequency/EM
related, gears, coupling, mechanical resonance, and bearings are
some examples. Other sources result from potential problems:
mechanical looseness, unbalance, and alignment. All these vibration
sources combine to create a measurable vibration signal. The vibration
sensor (accelerometer, proximity probe, velocity probe, etc.) produces
a multi-tone signature where each tone represents the vibration from a
specific mechanical source.

9
 IEPE Accelerometers
Direct Connection
Advantages
Simple and easy to use
Built-in microelectronics
Simple constant current signal conditioner
(18-30 VDC ; 2 mA)
Limitations
Temperature range: max 250 F (some 325 F)
Fixed sensitivity

The machinery monitoring system includes a data acquisition subsystem with

I/O matched for the vibration sensors to be used on the machinery. One of
the most common machinery vibration sensors is the piezoelectric
accelerometer. Accelerometers are a active sensor type, needing electrical
power supply. IEPE power is typically used for accelerometers.

IEPE refers to a type of transducers that are packaged with a built-in charge
amplifier or voltage amplifier. IEPE is an acronym for Integral Electronic
Piezoelectric. Because the charge produced by an accelerometer is very
small, the electrical signal produced by the transducer is susceptible to noise,
and sensitive electronics must be used to amplify and condition the signal.
IEPE makes the logical step of integrating the sensitive electronics as close
as possible to the transducer to ensure better noise immunity and more
convenient packaging.

IEPE signal conditioning provides a constant-current source to power

internally amplified sensors. All major accelerometer suppliers have their own
equivalent solution, such as ICP from PCB Piezotronics, Isotron from
Endevco, DeltaTron from Brel & Kjaer, and Piezotron from Kistler.

The major advantage of the IEPE accelerometer is that it is simple and easy
to use due to the built-in microelectronics and the simple conditioner required.

Limitations are a limited temperature range, especially for high temperatures,

and a fixed sensitivity.

10
 Tachometers

Measure
Angular position
Angular speed (rpm)
Used for
Order analysis
Order tracking
Angular averaging

A second key sensor for machinery monitoring systems is the

tachometer.

When dealing with rotating machines, it is important to be able to relate

any measurement from an accelerometer or a microphone to the
actual rotational speed of the machine under test. A tachometer will
basically track the angular position of a shaft versus time and so lead
to the measurement of the angular speed (commonly expressed in
rpm, revolutions per minute).

More than providing this angular speed information, the signal from the
tachometer is needed to perform advanced analysis such as order
tracking, order analysis, and angular averaging.

It is important that the tachometer signal be digitized at a high sample

rate, and simultaneously with the vibration sensors. For example,
most machinery vibration systems use an analog input simultaneously
sampled with vibration. Most data acquisition systems sample the
tachometer at 11 times the rotational frequency of the fastest moving
mechanical component on the machine.

11
 Harmonics of a Fan

4th order

7th order
1st order
Hz

55

385
220
3,300 RPM = 55 RPS

Lets look at a quick example:

When we acquire the vibration of a PC cooling fan. The major sources

include:

1. Imbalance of the rotor. It generates the vibration at the frequency of

the rotating speed. This is often called it the 1st order harmonic of
rotating speed.
2. Electric-magnetic force from the coil. This fan has 4 coils, which
drives the fan 4 times per revolution. So the vibration contributed by
coil is at the frequency 4 times the rotating speed, so we call it the
4th order.
3. 7 blades of the fan. They generates the vibration at 7th order.
4. The harmonics of E-M force, 8th, 12th, and so on orders.

So if the machine is running at 3300 RPM (55Hz), we would set our

sampling rate at 11 times 55 times 12 or 7260 samples per second.

12
 Data Acquisition Considerations
Number of Input Channels
Dynamic Range
Sampling rate
DSA Digital Filter vs. 8th Order Analog Bessel

IEPE signal conditioning 20 Bessel, Fc=15 kHz

Bessel, Fc=22.5 kHz
Bessel, Fc=30kHz
0
DSA Digital Filter

Simultaneous Sampling -20

Analog Bessel Filter
attenuates signals

Filter Response(dB)
in band of interest
-40

Anti-Aliasing Filters
-60

-80
Signal
Bandwidth
-100

AC/DC Coupling high pass filter

F Nyquist
NI 4472 at
-120
102.4 kS/sec F Nyquist
150 kS/sec
-140
0 10000 20000 30000 40000 50000 60000 70000 80000

Input Voltage Range Frequency (Hz)

Analysis of data is only as accurate as the data that is collected. Attention to data acquisition system
specifications is equally as important as selection of sensors and analysis.
Accelerometers and other transducers convert vibration into a voltage. Modern MCM systems
digitize this voltage for transfer to a computer for analysis. This brings us to the next element of a
machine monitoring system that works with dynamic vibration.
This acquisition hardware might be a plug-in instrument that resides in an industrial computer
(PXI/CompactPCI), a desktop PC, or an industrial distributed I/O system such as CompactRIO.
National Instruments offers a number of options for hardware that performs this function. We will get
to these in a moment. For now, lets consider some common requirements.
Dynamic range characterizes how well you can distinguish a low-amplitude signal in the presence
of high-amplitude signals. A high dynamic range ensures that you will not miss low amplitude
components that are sometimes key to successful analysis. The latest dynamic signal acquisition
board from National Instruments offers 110 dB spurious free dynamic range.
Anti-aliasing filters are required to avoid aliasing that could potentially ruin your measurement.
Anti-aliasing filters are low-pass filters, meaning that they reduce errors caused by the resonance
frequency of the accelerometer, as discussed earlier.
The sampling frequency is usually driven by the maximum rotational speed of the machine and
the highest order of interest. As a rule of thumb, min sampling rate = 11 * max rotational speed *
max order or harmonic of interest.
Simultaneous sampling ensures that you gather useful cross-channel phase information
Multiple input gains allow the user to take advantage of the full dynamic range of the analyzer, on
a per channel basis
Finally, built-in signal conditioning for accelerometers and microphones (often a polarization
voltage) is a nice feature, especially where space is a concern.
The NI 4472 data acquisition device is available for CompactPCI and PXI computing platforms. This
device provides eight simultaneously sampled inputs with 110 db dynamic range. It offers sampling
rates to 104.2 kS/s with a 47 kHz bandwidth using built in hardware tracking anti-aliasing filters. The
hardware also provides piezoelectric power for accelerometers and offers both AC and DC coupling.
Any number of NI-4472 devices can be utilized in a single or in multiple chassis to provide the
channel count needed for the application. A similar device, the NI-9233 is available for CompactRIO.

13
 Anti-Aliasing

Shannon sampling theorem

The maximum frequency (Nyquist frequency: fN) that can
be analyzed is given by
fN = fs/2 fs: sampling frequency

Improperly sampled Properly sampled

Lets take a look at anti-aliasing a bit more closely.

According to Shannon sampling theorem, the highest frequency

(Nyquist frequency: fN) that can be analyzed is fN = fs/2, where fs is the
sampling frequency. Any analog frequency greater than fN will, after
sampling, appear as a frequency between 0 and fN. Such a frequency
is known as an alias frequency. In the digital (sampled) domain, there
is no way to distinguish these alias frequencies from the frequencies
that actually lie between 0 and fN. Therefore, these alias frequencies
need to be removed from the analog signal before sampling by the A/D
converter.

Anti-Aliasing analog front ends are the most important feature of a

machinery vibration monitoring application.

14
 Signal Conditioning
DC and AC Coupling DC Coupling = AC+DC
AC Coupling = AC AC
5 volts
DC Coupling = AC+DC
DC
IEPE = Integrated
Circuit Piezoelectric 0 volts
built-in charge amplifier
or voltage amplifier AC Coupling = NO DC

Since most vibration sensors use a 24V DC power source, AC coupling is

required to remove the bias voltage from the vibration signal.

AC coupling consists of using a capacitor to filter out the DC signal

component from a signal with both AC and DC components. The capacitor
must be in series with the signal. AC coupling is useful because the DC
component of a signal acts as a voltage offset, and removing it from the
signal can increase the resolution of signal measurements. AC coupling is
also known as capacitive coupling.

DC coupling describes any voltage signal acquisition in which both AC and

DC components are measured.

IEPE technology is marketed under several more recognizable brand

names. Although other companies make IEPE based accelerometers, this
does not imply that they are compatible with equipment that claims
Integrated Circuit Piezoelectric compatibility. One of the key variations
from company to company is the amount of current necessary to power
the sensor.

15
 Signal Processing
Extracts features from vibration signals
Fourier Transform is most common tool
Order Analysis identifies harmonics of rotation
Other Analysis techniques
Envelope Analysis
Modulation analysis
Wavelets

Now that we have a solid data acquisition system in place, we can focus our
attention on the mathematics used to extract mechanical health indication
features from the vibration signal.

The most common signal processing tool used to extract machinery health
indicators from machine vibration signals is the Fast Fourier Transform or
FFT.

The FFT can be extended to represent harmonics of rotation, with additional

signal processing called order analysis.

Additional signal processing is used for specific applications including

Envelope Analysis, Modulation analysis, and wavelets.

We will focus on the fundamental FFT next.

16
 Typical Spectrum Showing Basic Faults
0.01
Velocity (ips)

unbalance

misalignment
0.001

bearing frequencies gear mesh frequencies

0.0001

100 1000 10000 100000

Frequency (Hz)

Courtesy of

The Fourier Transform is a signal processing tool used to identify

repetitions in a data set. Since a machine rotates, its vibration signals
repeat each rotation. The Fourier Transform identifies these repetitive
signals and allows the maintenance team to monitor the repetitive
vibration from individual mechanical components such as bearings and
gears.

Using a carefully selected data acquisition system to acquire the data,

the next step in machinery monitoring for vibration is to perform
frequency analysis. This graphic shows the typical vibration frequency
of several machine vibration phenomenon. While the machine being
monitored or under test may be rotating at 30 to 200 hz, its bearing
fault frequencies may be 10 or 20 times as high as rotational
frequency. Similarly gear fault frequencies may be 20 to 50 times as
high as rotational speed.

The workhorse analysis tool for vibration monitoring is the Fast Fourier
Transform, or FFT. This tool allows us to focus attention on particular
frequency space to completely understand the vibration characteristics
of the mechanical components, including amplitude, frequency, phase,
harmonics, sidebands, and so forth.

17
 Gear Mesh Example
Gear mesh amplitudes
much higher than
running speed 1XGMF
2XGMF

Gear mesh frequency 1Xrunning speed

and sidebands visible in 1XTS sidebands

spectrum
Number of Sidebands
and distance from center 5 10 15 20
Frequency (orders
25 30

frequency multiples of rotational

speed)
ZOOM FFT

Courtesy of

An extension to the FFT is the zoom FFT. The resolution of the FFT
result is dependent on the amount of data collected. The zoom FFT
stores up consecutive blocks of data until the desired frequency
resolution of the X-axis is obtained. Further more, the zoom-FFT only
analyzes the raw signal for repetitions in the desired frequency range.

Gear frequencies are an example use case for zoom-FFT. Gear mesh
amplitudes are at much higher frequencies than running speed. The
gear mesh frequency and sidebands are visible in the spectrum. Here,
a zoom-FFT will help to further understand the sideband peaks, their
relationship to the center frequency, amplitude ratios, and so forth.
Often, shaft sidebands around gearmesh suggest input shaft
problems.

A computer-based machinery monitoring and diagnostic tool provides

the engineer with the ability to easily adjust FFT and Order spectrum
tools to easily analyze complex problems such as gear-mesh
frequency analysis.

18
 Orders

mm/s Spectrum of the fan

housing vibration,
with the fan running at
1X
600 RPM
2X

.5X 4X 5.5X
3X

600
1 1200
2 1800
3 2400
4 3200
5.5
600 RPM frequency (CPM)
frequency (orders)

Express frequency in
terms of multiples of
the shaft running speed

Another extension to the FFT is Order Analysis. With order analysis, the
rotational speed of the machine is used to normalize the x-axis of the
resulting FFT to show harmonics or rotation or angular position rather than
harmonics of time, or frequency.

In this example, the tachometer signal us used to identify the rotational speed
of the fan, and to normalize the frequency axis of the resulting FFT.

A more complete order analysis technique is to transform the data from the
time domain to angular domain with a tool called Resampling. With
Resampling, any FFT skew in the graph is removed by analyzing equal
angular sampled data. This signal processing technique is very common for
machinery which changes speed such as variable speed drives, turbo
machinery, and so on.

19
 Synchronous & Non-Synchronous Frequencies

mm/s

Synchronous
frequencies are 1X
whole number 2X
multiples of the .5X 3X
4X 5.5X

shaft speed
600 1200 1800 2400 3200
frequency (CPM)

Anything else is non-synchronous

When reviewing the Frequency or Order spectrum (FFT) of the vibration,

vibration signals are often classified as synchronous and non-synchronous
vibration frequencies.

Synchronous frequencies occur at whole number multiples of shaft speed.

Non-Synchronous frequencies are everything else.

Gear Mesh, Balance, Mechanical Looseness, and blade pass frequencies are
repetitive vibrations that are synchronous.

Roller element bearing vibrations are repetitive, yet are typically non-
synchronous due to their mechanical anti-friction design.

20
 Bearings

Bearings & cage move at non-synchronous rates

BPFO = Ball Pass Frequency Outer = frequency at which a ball
will go past a defect on the outer race.
BPFI = Ball Pass Frequency Inner
BSF = Ball Spin Frequency = rate at which balls rotate
FTF = Fundamental Train Frequency = rate at which cage
rotates.

Here is a closer look at bearing frequencies. As you can see, vibration

signature analysis can tell quite a lot about bearing vibrations.

21
 Bearings

BPFI and BPFO usually show up first

Shaft RPM sidebands may develop around these frequencies.
Harmonics of these frequencies are common
FTF is always below 1X.
Formulas give fault frequencies as functions of bearing
geometries...

The non-synchronous nature of bearing vibrations is seen in the FFT graphic

above. As one monitors the four major bearing frequencies, the ball pass
frequencies and shaft RPM sidebands become a leading indicator of
impending bearing failure.

When a machine changes speeds, the FFT, combined with zoom-FFT, and
order analysis becomes a key signal processing element in the machinery
monitoring and overall maintenance programs.

22
 These are tabulated in
a bearing atlas

Pd = Pitch diameter
n = number of balls
Bd = Ball diameter
= Contact angle

As a side note, the bearing fault frequencies are related to the mechanical
design of the bearings.

23
 Trending over time key to changes
Collecting data over time provides trends in
vibration parameters
Technical Data Management allows storage of
signatures for off-line signal analysis
Both are key elements of an intelligent maintenance
systems

Now that we have a tool to track the magnitude or level of vibration from key
mechanical components, we need to use this information for reports and
predictions of failure.

Using a trend plot of say bearing vibration, we can monitoring the trend over
time and determine whether the vibration is rising, or remaining the same.
Rising vibration levels tend to indicate a failure waiting to happen. Using
vibration severity charts, past experiences, design knowledge from the
supplier, and so on, we can set alarms on these vibration levels to tell the
maintenance team when to order replacement bearings and to schedule
maintenance.

Going further, the maintenance team often chooses to store the raw vibration
signal such that it can be further analyzed off-line and compare to periodic
recordings over time. These raw signals can be used for further diagnostics
activities, and to double check the alarm trend levels from above.

Both data management techniques are common in machinery vibration

monitoring and maintenance applications.

24
 Datalogging Features in LabVIEW 8.0

Using a historical trending and alarming software, we can track the results of
the FFT for any and all machines and mechanical components of the
machine. The alarming system will notify the maintenance team if a vibration
level has risen above a specific level. The historical trending system will
provide a history of the vibration levels, and allow for vibration level reviews
both before and after a repair has been completed. The historical trending
system also serves then to verify that the maintenance activity is successful.

In LabVIEW 8 Datalogging and Supervisory Control (DSC), the core

functionality logging, alarming, scaling, and more is seamlessly integrated
into the core LabVIEW development environment via a shared variable, or
TAG. When you have the DSC module installed, your shared variable
properties page is modified to show the additional functionality. And all of it is
configuration-based, allowing you to quickly navigate through the pages,
configure your system, and LabVIEW will generate all of the necessary code
for you in the background.

25
 Configuring Alarms and Trends

With an alarming tool, the maintenance team has access to the alarm
settings, and programmatic actions when alarms occur.

One example of alarm actions is to blink a display, or to add an entry to a

machinery alarm display. Additional actions such as sending email or
invoking pagers are also common.

26
 Locate Your Test Data and Load All of It
Manage

Inspect

Analyze

Report

Connect
Generic Plug-In Interface
Automate

DIAdem, ASCII, VI Logger SQL/ODBC Custom

LabVIEW EXCEL LabVIEW DSC formats

When storing raw vibration signals from a large number of machines and
sensors, we create a technical data management problem.

As a result, you end up storing valuable engineering data in a variety of

formats across numerous locations. Using the intuitive technical data
management tool such as DIAdem, you can locate and manage data stored
in a variety of formats and locations, from both databases and flat files (SQL,
ASAM, Citadel databases and ASCII, binary, and Excel files).

This allows the maintenance team to keep track of and utilize all the data
collected from the vibration measurement devices employed in the plant.

With a data mining feature of the technical data management system, it is

easy to locate specific data files for off-line and comparative analysis,
regardless of where they are located, and whether they are stored in the
same format.

27
 Inspect Your Test Data
Manage

Inspect

Analyze

Report

Connect

Automate Identify problem spots

Compare test runs
Copy & delete data interactively

Now that the data is accessible, the maintenance team will want to preview
the data prior and interactively analyze the data prior to making formal
reports.

Visual data inspection helps you investigate why certain events happen
during your tests. You can use DIAdem to correlate several test runs and
visually compare results. You also can zoom in, scroll across, and
interactively analyze graphs of your measurements to quickly and fully
visualize your test results.

28
 Report your Test Data
Manage

Inspect

Analyze

Report

Connect

Automate Design reusable engineering focused reports

Collaborate with coworkers

Now that the data is accessible and analysis completed, reporting is the next
step in the vibration data aspect of maintenance. Reports are used to both
justify repairs and to report the success of a maintenance activity.

Communicating results via reports is a key step in any engineering process.

Consistent reports give your organization and your customers a better
understanding of the engineering process and the progress of your work.
DIAdem offers an easy-to-use, graphical, drag-and-drop environment for
creating report templates that you can share and re-use throughout your
organization.

29
 Putting it all together

Multiple machine
monitoring nodes
integrated together over a
network
Local signal processing
Data logging at a host
engineering workstation
Signal Processing to
extract features

When we put all the components together, we have a complete machinery

maintenance system. By embedding signal processing at the local machine
and instrumentation system level, we are able to produce trends and alarms
for each individual machine component that is of interest to the maintenance
teams.

By periodically logging vibration signals, we also create an off-line

engineering tool for further and advanced diagnostics of machinery vibration
and other related parameters.

Using these tools in a networked environment allows for data sharing and
automatic communication to other systems in the plant, including the
computerized scheduling systems for parts, personnel, and production.

The following examples depict successful implementation of machinery

vibration applications.

30
Instituto de Investigations Electricas SICAD
for PEMEX and CFE
Challenge:
Develop a cost effective and advanced
machine monitoring and diagnostic tool
for Oil Platforms and Power Generation
Flexible, Cost Effective, Advanced
Process and Vibration Monitoring
NI Tools
PXI, DSA, Counter Timer
LabVIEW, S&V, OAT, RT
Results
12 systems deployed
Pemex asking for more
Adapted for portable solution

31
 Dresser-Rand VAM System
Low Speed Shaft Key Phaser
x x x
Turbine/
y Gear Box y
Electric Motor y x x
x
x Compressor
y y y y
Key
Phaser High Speed Shaft
Vibration Probes/ 2 leads:
Acceleration/velocity
Challenge: To develop a comprehensive, cost effective, and advanced compressor remote
monitoring, diagnostics, and data capture system. Systems to be deployed for Oil and Gas
Industry Installations.
NI Tools Used: PXI DSA, 6602, LabVIEW Pro, S&V, OAT, Internet Tools
Results: RECON Total is Dresser-Rands flagship condition monitoring system that provides on-
line, fully integrated, fully remote, core knowledge base capabilities with comprehensive
vibration, performance, process, and stress wave analysis.

32
Duke Energy Reactor Pump Vibration
Monitor
Challenge
Provide a combined system for 32
vibration channels in four machinery
locations
NI Tools
PXI, LabVIEW, Order Analysis Tools
Results
Real-Time Monitoring
Historical Data
Transient Data
Alarming on Vibration parameters
Adaptable to other process and
control variables

33
 Vibdaq Solutions for TurboMachinery
Challenge
Develop a portable vibration
diagnostics tool for turbo machinery
applications
Needs flexibility, scalability, graphics,
and advanced signal processing
NI Tools
LabVIEW, PXI, DSA, Order Analysis,
USB DAQ
Solution
Leveraging off the shelf technologies
Vibedaq now has a strong competitive
posture in the portable machine
diagnostics applications market

34
Power Systems Manufacturing DDAQ

Challenge
Develop a dynamic pressure monitoring
solution for Gas turbine pressure pulsations
Interface the on-line system to control systems
for operator use
Tools
NI DSA, LabVIEW, Signal Processing
Results
A superior early warning device with multiple
screen views to monitor overall turbine
performance or focus on individual combustors

35
 National Renewable Energy Labs (NREL)
Challenge: To develop a power,
vibration monitoring, and control
solution for study of Wind Turbine
mechanical systems. System
needs to be advanced, flexible,
and cost effective
NI Tools Used: PXI AI, AO, DSA,
LabVIEW RT, OAT, S&V
Results: Vibration Systems on par
with typical systems, plus
integrated with electrical power
quality/metering, and control
systems

36
 The NI Computer-Based Monitoring Option

Frequency Analysis
Networked Access
Flexible Configuration
Time Synchronized
Data Logging
Orbit Plot
Bode Plot
Polar Plot
Order Spectrum
Shaft Centerline
Trend Charts
Data Archives
Alarming
Transient Recording
Sequence of Events

Each of the preceding examples leverages an architecture of a

machine monitoring solution.

Data is collected and analyzed at the local data acquisition system

level. Trend and alarm data is sent to the control room and the
maintenance team workstations.

An engineering workstation stores and provides off-line access to

vibration signatures that are captured with either on-line data
acquisition equipment or portable, off-line data acquisition equipment.

National Instruments provides I/O solutions to meet the requirements

of most sensors, including vibration. Further, National Instruments
offers an extensive interface library to allow for communication with
PLCs and other plant data collection and control equipments.

37
Sound and Vibration Platform

USB Handheld Devices

Embedded Controllers
LabVIEW RT and FPGA

Programmable Automation
Controllers RMS levels
PXI Industrial Controllers

Portable PCs
Desktop PCs

38
 Solutions
www.ni.com/industrial/machine_vibration.htm
Cal-Bay Systems: REMS100
http://www.calbay.com/REMS.htm
Omnia Technologies: OVT1000
http://optimation.us/omnia/index.asp, http://vibdaq.com
Nexjen: VTS
http://www.nexjen.com/nexjen/portfolio/customerdefined.htm
FAG Industrial Services: X1
http://www.fag-industrial-services.com/site/en/
Advanced Engine Technologies: TraceVIEW
http://www.aetco.com/documents/TruTrace.pdf
Dynalco: RT-Online
http://www.dynalco.com/prod_details.cfm?product_id=168
Spectraquest: Vibquest
http://www.spectraquest.com/products/vibraquest/index.html
Power Engineering: Hydro Power Plant Monitoring
http://www.powerengineering.com/
Structural Integrity: Vibration Consulting
http://www.structint.com/analytical/vibration.htm
PCB: Vibration Sensors
http://www.pcb.com/

There are a number of machinery reliability experts and systems suppliers

available to augment the maintenance teams efforts in improving uptime of
machinery. Several examples of these companies are listed above.

39
 Conclusion
Vibration is a key parameter for asset management
of industrial machinery
Distributed intelligent solutions provide an excellent
means of local monitoring and remote data logging
Call on NI for any of your machinery vibration needs
www.ni.com/industrial/machine_vibration.htm

Vibration is a key aspect of machinery maintenance applications. Vibration

provides significant in-sight into the health of mechanical machinery
components.

Distributed intelligent solutions provide an excellent tool for local signal

acquisition, analysis, and data logging.

These vibration solutions can integrate other measurements such as

temperature, electrical power, and operational parameters, and even oil
analysis. Extending vibration monitoring applications to include other aspects
of machinery monitoring, can further improve the usefulness of the data
acquisition system.

National Instruments flexible, distributed, and capable solutions provide a

solid foundation for collecting data and analyzing data that is key to
successful maintenance operations.

For more information consider the following sources:

www.ni.com/industrial.machine_vibration.htm
Links from the referenced suppliers slide
www.vibinst.org
http://www.mfpt.org/
http://www.reliabilityweb.com/tutorials.htm

40