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Machine Condition Monitoring


Metra Mess- und Frequenztechnik Radebeul / Germany Metra Mess- und Frequenztechnik Radebeul / Germany 2. Machine Vibration Monitoring ... – PowerPoint PPT presentation

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Title: Machine Condition Monitoring

Machine Condition Monitoring
  • Introduction

Metra Mess- und Frequenztechnik Radebeul /
Machine Vibration Monitoring
Machine Maintenance
  • Predictive Maintenance
  • Monitoring techniques include vibration, acoustic
    noise, temperature, oil condition
  • Helps to predict machine failure with sufficient
    accuracy to enable repair before breakdown
  • Maintenance can be better planned
  • Increased plant availability
  • Reduced maintenance costs
  • Better product quality
  • Increased plant safety
  • Traditional Maintenance
  • Periodic shutdown and overhaul schedule
  • Production is stopped, off-line machinery is
    inspected for wear and wear-prone components
  • Bearings, fans, gear boxes and other parts are
    replaced, irrespective of their potential to
    operate for a longer time
  • Between these scheduled repairs unpredicted plant
    breakdowns cause production loss
  • Unscheduled repairs may be costly

Machine Vibration Monitoring
  • Advantages of Monitoring Vibration
  • Vibration magnitude is proportional to the
    magnitude of the problem
  • Vibration measurement is non-invasive
  • Most faults show increased vibration in an early
    stage of the deterioration sequence
  • Vibration can be measured instantaneously
  • Vibration can indicate severity and deterioration
    rate of a fault
  • Vibration can help to find the location of the
  • Vibration can help to find the cause of the fault

Machine Vibration Monitoring
  • How Machine Vibration is Generated
  • Operating machinery produces vibration due to its
    rotational or linear motion
  • Increasing trends towards a higher level indicate
    emerging problems
  • Typical problems arise through - misalignment of
    drive train components- worn or damaged
    bearings- load asymmetry due to debris adhesion
    on rotary parts like fans etc.- incorrect
  • Vibration generally occurs with its major
    component perpendicular to the rotational axis of
    the load transmission shaft
  • The amount of vibration depends on - the
    stiffness and geometry of the machine's structure
    - the machine foundation - the speed of
    rotation of the shaft

Machine Vibration Monitoring

Vibration Monitoring
  • Permanent Monitoring
  • Vibration switches
  • Vibration severity monitors
  • Spectrum monitors
  • Regular Patrol
  • Hand-Held vibration severity meters
  • FFT analyzers
  • Data loggers

Machine Vibration Monitoring
  • Vibration Severity Monitoring
  • Widespread and simple method for vibration
  • Measurement of vibration velocity, also called
    vibration severity in mm/s
  • Vibration severity is a measure of energy of the
    emitted vibration
  • Frequency range 10 to 1000 Hz
  • ISO 10816
  • The standard gives recommendations for the
    evaluation of machine vibration by measurements
    on non-rotating parts

Machine Vibration Monitoring
  • Recommendations for Sensor Locations to ISO
  • Vibration measurements on machines should be made
    preferably at the housing of bearings or nearby
    measuring points
  • For routine monitoring it is sufficient in many
    cases to measure vibration either in vertical or
    in horizontal direction
  • Rigidly mounted machines with horizontal shafts
    have their highest vibration levels mostly in a
    horizontal direction.
  • Flexibly mounted machines may have high vertical
    components of vibration, too
  • For inspections, vibration should be measured in
    all three directions (vertical, horizontal and
    axial) at all bearings.

Machine Vibration Monitoring
  • The following illustrations show some examples
    for suitable measuring points

Machine Vibration Monitoring
Machine Vibration Monitoring
  • Recommendations for measuring points at different
    types of machines can also be found in ISO
    13373-1. horizontal

Machine Vibration Monitoring
  • Vibration Severity Limits to ISO 10816-1
  • If no reference values of vibration severity are
    available on the relevant machine, the
    recommendations of ISO 10816-1 can be used
  • Permissible values of the vibration severity are
    given for different machine types
  • The basis of the assessment is the maximum value
    of all measured points on the machine

Machine Vibration Monitoring
  • Vibration Measurement on Reciprocating Engines to
    ISO 10816-6
  • Reciprocating engines, like combustion engines
    and compressors, are characterized by backward
    and forward going masses.
  • The vibration generated by this motion, is higher
    than the vibration of rotating machinery.
  • ISO 10816-6 includes recommendations for the
    assessment of vibrations of reciprocating
  • The measured quantities are the RMS values of
    acceleration, velocity and displacement.
  • They are measured at the machine block in all
    three axes of the room. The recommended frequency
    range reaches from 2 Hz up to 1000 Hz.
  • By means of the measured values of all three
    vibration quantities, the reciprocating engine
    may be classified as belonging to a particular
    class of assessment.
  • The following table allows this classification.
    At first read the relevant vibration severity
    level for all three measured vibration
    quantities. The decisive class is the highest of
    these three determined severity classes. In the
    right part of the table you find the degree of
    machine condition in dependence on the machine
    class (depending on size, construction, assembly
    and speed of the machine).

Machine Vibration Monitoring
  • Vibration Measurement on Reciprocating Engines
    to ISO 10816-6
  • A New machines
  • B Continuous running without restriction possible