Spectrum 76 May 2015

this

issue:

§ Balancing Machines Explained. Part 1 (pg 5)

by MadBalancingEngineer

§ Evolving Reliability at Penrose Mill (pg 16)

by Craig Allan

§ 2015 conference details (pg 12)

§ Test your Knowledge - Part 40 of a Series (pg 34)

Autumn 2015 - ISSUE 76

the official journal of the vibrations association of new zealand

SPECTRUM

ISSUE 76 –May 2015

ISSN 1173-793X

EDITOR

Angie Hurricks Ph 021 239 4572 Email: [email protected],nz

PUBLISHER

Frans Taris Email: [email protected]

New Zealand Spectrum is published quarterly by the Vibrations Association of New Zealand Inc. The journal is designed to cover all aspects of the vibration field, and is received by all VANZ members including corporate members.

Contributions to Spectrum are welcome.

Please address material to:

Angie Hurricks Spectrum Editor c/o 358 Waerenga Road,

R.D.1, Te Kauwhata, 3781

Waikato, New Zealand

or [email protected]

Statements made or opinions expressed in Spectrum are not necessarily the views of VANZ or its Officers and Committee.

President Cameron Blackbourn [email protected]

Treasurer Graeme Finch Email: [email protected]

Secretary Angie Hurricks Email: [email protected]

Please address all VANZ correspondence to

VANZ

PO Box 2122

Shortland Street

Auckland

Web Site

www.vanz.org.nz

page 2

presidents report

Welcome to the first E-issue of Spectrum, this is one of the initiatives that we are rolling out to members based on our survey results.

Hopefully all of the LinkedIn users amongst us have joined the VANZ group by now. The idea of this group is to allow members to interact and share problems and ideas in an arena where everyone’s contributions and questions can be treated respectfully. If you missed the initial invite to join or haven’t used LinkedIn before simply search for VANZ and request to join the group. Membership is restricted to VANZ members only.

Conference is almost here and we have released the timetable and speakers lists, check out the website www.vanz.org.nz if you have not seen it yet.

Don’t forget to come along and experience our new hands on awareness day program. There will be opportunities to try out techniques and speak with experienced practitioners in small groups face to face. You don’t have to feel uncomfortable about asking basic questions in front of a whole room of people!

As always please email me [email protected] if you would like to contribute in any way. I look forward to catching up with you all again this year.

Regards

VANZ President

Cameron Blackbourn

http://www.vanz.org.nz

mailto:[email protected]

Angie

Conference time is rolling around again and VANZ is a hive of activity planning this years symposium so all who attend can benefit and take away new information and techniques not to mention the latest toys to roll out in to the field.

This years major sponsors are NVMS and UE Systems, the Wairakei Resort has been chosen as our venue of choice and this year our guest speaker is Bob Craft from Bently Nevada, U.S.A. For more info on our keynote check out his bio in this issue.

The Awareness Day has been given a shake up and a new format of ‘hands on’ presentations will be the order of the day where you can see live demonstrations and have a go with Condition Monitoring techniques you may be unfamiliar with. These sessions will be running throughout the day.

As you may have noticed our new e-book format for Spectrum has been implemented and is up

and going, it presents more opportunities for our readers to get in touch with our advertisers so both parties can get more out of each issue.

The VANZ website has had a revamp and we’re continuing to add to it and improving its functionality so our members and supporters have a network of resources at their disposal. If you haven’t seen it lately I urge you to check it out and see who is having a trade stand at the conference this year.

Many thanks go to our advertisers who continue to support us, as always it is much appreciated!

Check out our conference timetable to see the who you’d like to see presenting and make the most of your time there, see you at the conference!

www.vanz.org.nz

Library Books Wanted!If you have any books/magazines/documents that you think VANZ would benefit from having in the collection, please make contact with a committee member/ Spectrum Editor through contact details. Also if you have any books/documents borrowed from the VANZ library please take the opportunity to bring them to the next conference so others can use the resources.

Help us to keep our library together!

editorial

Robert S. (Bob) CraftField Application Engineer Bently Nevada, a wholly owned subsidiary of General Electric

Robert S. (Bob) Craft, a 1978 graduate of

Rensselaer Polytechnic Institute with a B.S.

in Mechanical Engineering, has over 35 years

of experience in the field of technology

based machinery condition monitoring and

evaluation systems. He started his test and

evaluation career in the fields of physical

oceanographic and environmental research

using both airborne remote and in-situ

data acquisition techniques. Bob spent 12

years conducting new construction and

commissioned submarine acoustic sea trials

and other underway and dockside sound and

vibration tests and developed and instructed

the course series that taught Ships Force on

TRIDENT class submarines how to use the

installed Noise and Vibration Monitoring

System for both ship silencing and machinery

condition analysis. He worked in the nuclear

power industry at Detroit Edison’s Enrico Fermi

Unit 2 Nuclear Generating Station, as the lead

vibration engineer, responsible for all aspects

of the facility’s vibration based predictive

maintenance program. While there, he

designed, built and installed several dedicated

on-line vibration and process parameter based

condition monitoring and evaluation systems,

resulting in improved monitoring of several

critical machine systems.

Bob has nearly 20 years of experience designing

and implementing condition monitoring and

evaluation systems as a supplier to the industry

working on Customer projects as diverse as

cruise ship propulsion pods, locomotives, paper

machines, wind turbines and petrochemical

processing facilities. Many of these systems

have included wireless elements. He has been

published in Plant Services magazine on the

topic of wireless sensor systems. He currently

serves as a Field Application Engineer with

Bently Nevada, a wholly owned subsidiary of

General Electric Company.

Collecting Observational Dataportable Vibration data collection programs provide Much More Value than Just the digitized data they Acquire

bob craft

Bently nevada Field

Application engineer

[email protected]

Adding human senses to your Portable Vibration data collection ActivitiesReliability professionals often tend to focus on

objectively measured data and forget about the fact

that the human senses and mind make up one of

the best data acquisition and evaluation systems

available. Four of our five senses provide a wealth

of information about the operational integrity of our

production systems, and if we talk about the food and

beverage industry, often the fifth comes into play!

Observations worth noting when evaluating

a system for indications of its reliability can

be divided into two categories; those that can

be quantified and those that cannot.

Quantifiable observations are typically structured for

consistency and can be represented by a numeric

value, which often has an associated alarm to alert the

reliability analyst when something is observed that needs

to be elevated as a concern, similar to alarms set on

vibration data. Qualitative observations typically cannot

be reduced to a finite, predictable set of numbers and

although often repeatable – think reusable – require

more detail than a set of numbers would allow.

The greatest value provided by a portable vibration data collection program

derives from the simple fact that, periodically, someone whose sole concern is the

functional reliability of the machine visits it specifically to evaluate its condition.

This article describes the easy way to record and communicate valuable qualitative

observations with your Bently nevada* sCOuT portable vibration data collector!

Oct .2013 • No.4 • Vol .33 ORBIT 47

DEPARTMENTS

Scout camp

GEA30831 OrbitV33N4_2013Oct_r3.indd 47 9/10/13 1:37 PM

Conference 2015

keynote speaker

continued

Balancing Machines Explained. Part 1

By MadBalancingEngineer

Introduction

There are three general categories of balancing machines;

* Soft bearing.

* Hard bearing.

* Full speed.

In part 1 of this series we will look at the theory, construction, operation and limitations of soft bearing balancing machines.

Theory.

Consider a rotor spinning along its longitudinal axis in free space i.e. no restraint to motion in any direction, referred to as a free-free state.

Let us say there is an eccentric mass which moves the centre of gravity away from the geometric centre by 0.05mm (50µm) as below. i.e. the rotor has an eccentricity “e” of 0.05 mm (50µm).

Let us say the rotor is spinning at 200 RPM. This rotor will spin around the centre of gravity and the geometric centre will follow a circular orbit with a diameter of 0.1mm (100µm). If we were to measure the motion of the outside periphery of the rotor with a proximity probe it would show an amplitude of 0.1mm peak to peak.

Now let us increase the RPM to 2000 RPM. The rotor will still rotate about the C of G and the amplitude of the rotor periphery will still be 0.1mm p-p.

Is this rotor unbalanced? Intuitively one would probably yes, because it has an eccentric mass. But let us look at the facts.

By definition a rotor is unbalanced if its centre of rotation and its centre of gravity are offset. In this case the centre of rotation is the centre of gravity. Also for a rotor to be unbalance there must be a force equal to m??r where ??is the radial velocity in radians per second and r is the offset of the centre of rotation from the centre of gravity in metres. In this case r is zero so this rotor is not unbalanced.

Now let us take the same rotor and put it in light bearings which are suspended by light beams which have a pivot at one end as in the diagram below.

i.e. a pendulum where the weight is rotating. Let us say the length of the pendulum is 100mm then the period of the pendulum is given by T= 2??L/g or in this case 0.634 seconds which makes the frequency 1.8 Hz

If we again spin the rotor at 200 RPM (3.33Hz) the rotor will rotate around its centre of gravity in the horizontal axis but will not have any motion in the vertical axis. i.e. the rotor will have an amplitude of 0.1mm in the horizontal direction. Because the centre of rotation and the centre of gravity are the same in the horizontal

Balancing Machines Explained. Part1 By

MadBalancingEngineer

Introduction. There are three general categories of balancing machines;

• Soft bearing. • Hard bearing. • Full speed.


Theory. Consider a rotor spinning along its longitudinal axis in free space i.e. no restraint to motion in any direction, referred to as a free-free state. Let us say there is an eccentric mass which moves the centre of gravity away from the geometric centre by 0.05mm (50µm) as below. i.e. the rotor has an eccentricity “e” of 0.05 mm (50µm). Let us say the rotor is spinning at 200 RPM. This rotor will spin around the centre of gravity and the geometric centre will follow a circular orbit with a diameter of 0.1mm (100µm). If we were to measure the motion of the outside periphery of the rotor with a proximity probe it would show an amplitude of 0.1mm peak to peak. Now let us increase the RPM to 2000 RPM. The rotor will still rotate about the C of G and the amplitude of the rotor periphery will still be 0.1mm p-p. Is this rotor unbalanced? Intuitively one would probably yes, because it has an eccentric mass. But let us look at the facts. By definition a rotor is unbalanced if its centre of rotation and its centre of gravity are offset. In this case the centre of rotation is the centre of gravity. Also for a rotor to be unbalance there must be a force equal to mω 2r where ω is the radial velocity in radians per second and r is the offset of the centre of rotation from the centre of gravity in metres. In this case r is zero so this rotor is not unbalanced. Now let us take the same rotor and put it in light bearings which are suspended by light beams which have a pivot at one end as in the diagram below.

0.05mm

C of G

Geometric Centre

Eccentric Mass

Free to move

Very stiff Pivot

Balancing Machines Explained. Part1 By

MadBalancingEngineer

Introduction. There are three general categories of balancing machines;

• Soft bearing. • Hard bearing. • Full speed.


Theory. Consider a rotor spinning along its longitudinal axis in free space i.e. no restraint to motion in any direction, referred to as a free-free state. Let us say there is an eccentric mass which moves the centre of gravity away from the geometric centre by 0.05mm (50µm) as below. i.e. the rotor has an eccentricity “e” of 0.05 mm (50µm). Let us say the rotor is spinning at 200 RPM. This rotor will spin around the centre of gravity and the geometric centre will follow a circular orbit with a diameter of 0.1mm (100µm). If we were to measure the motion of the outside periphery of the rotor with a proximity probe it would show an amplitude of 0.1mm peak to peak. Now let us increase the RPM to 2000 RPM. The rotor will still rotate about the C of G and the amplitude of the rotor periphery will still be 0.1mm p-p. Is this rotor unbalanced? Intuitively one would probably yes, because it has an eccentric mass. But let us look at the facts. By definition a rotor is unbalanced if its centre of rotation and its centre of gravity are offset. In this case the centre of rotation is the centre of gravity. Also for a rotor to be unbalance there must be a force equal to mω 2r where ω is the radial velocity in radians per second and r is the offset of the centre of rotation from the centre of gravity in metres. In this case r is zero so this rotor is not unbalanced. Now let us take the same rotor and put it in light bearings which are suspended by light beams which have a pivot at one end as in the diagram below.

0.05mm

C of G

Geometric Centre

Eccentric Mass

Free to move

Very stiff Pivot

plane there is no force in this direction, however because the rotor is restrained in the vertical direction there will be a force equal to m??r in the vertical axis.

Note that this is the ideal case where the bearings and the pendulum arms have no mass and therefore do not alter the mass distribution of the system.

Also note that because the motion is very small the effect of gravity on the motion can be ignored.

If we were to spin the rotor at 2000 RPM the horizontal motion would remain 0.1mm but the vertical force would the 100 times greater.

Note that if we were to spin the rotor at 108 RPM (the natural frequency of the pendulum) the amplitude would increase as the resonance of the system would be excited.

The soft bearing balancing machine.

Below are four variations of support used in soft bearing balancing machines. In all of these designs the rotor is free to move in the horizontal direction but very stiff in the vertical direction.

All of these suspension systems behave like a

pendulum and therefore have a natural frequency which would be typically around 100 RPM.

For soft bearing balancing machines the rotor

must be run above the resonant frequency and to prevent high amplitudes the motion is locked until above this frequency.

Just as in the ideal case above increasing the rotor speed once above the natural frequency does not increase the amplitude or the sensitivity of the balancing machine.

Benefits.

Because these machines typically run at low speed (200 RPM) the forces on the support systems are low and therefore the balancing machine can be made relatively light and can therefore be made to be transportable. There is consequently less risk to the rotor as is does not have to be transported to the balancing machine.

Sensitivity.

The sensitivity of a soft bearing balancing machine is governed by the parasitic mass, e.g. any mass which moves with the rotor but is not turning at the same speed as the rotor. i.e. the support rollers and roller support assemblies.

What the parasitic mass does is to reduce the effect eccentricity of the actual imbalance on the rotor and therefore reduces the measured motion for a given imbalance. The heavier the rotor with respect to the parasitic mass the more sensitive the balance.

ISO 1940 Balance Standard and the Soft

bearing balance machine.

The ISO 1940 balance standard gives a balance grade or “G” value for a rotor depending on the type of machine construction and its function.

The balance grade has the units of mm/s and is the maximum allowed radial velocity if the rotor was in a free / free state i.e. with no restraints. This velocity defines the maximum eccentricity of the rotor which is only dependent on the rotor speed and is not affected by the rotor mass.

As an example if we have a rotor with an operation

Linear Bearing

Rubber Shear blocks

I nverted reed

Pendulum

i.e. a pendulum where the weight is rotating. Let us say the length of the pendulum is 100mm then the period of the pendulum is given by T= 2π√L/g or in this case 0.634 seconds which makes the frequency 1.8 Hz If we again spin the rotor at 200 RPM (3.33Hz) the rotor will rotate around its centre of gravity in the horizontal axis but will not have any motion in the vertical axis. i.e. the rotor will have an amplitude of 0.1mm in the horizontal direction. Because the centre of rotation and the centre of gravity are the same in the horizontal plane there is no force in this direction, however because the rotor is restrained in the vertical direction there will be a force equal to mω 2r in the vertical axis. Note that this is the ideal case where the bearings and the pendulum arms have no mass and therefore do not alter the mass distribution of the system. Also note that because the motion is very small the effect of gravity on the motion can be ignored. If we were to spin the rotor at 2000 RPM the horizontal motion would remain 0.1mm but the vertical force would the 100 times greater. Note that if we were to spin the rotor at 108 RPM (the natural frequency of the pendulum) the amplitude would increase as the resonance of the system would be excited.

The soft bearing balancing machine. Below are four variations of support used in soft bearing balancing machines. In all of these designs the rotor is free to move in the horizontal direction but very stiff in the vertical direction. All of these suspension systems behave like a pendulum and therefore have a natural frequency which would be typically around 100 RPM. For soft bearing balancing machines the rotor must be run above the resonant frequency and to prevent high amplitudes the motion is locked until above this frequency. Just as in the ideal case above increasing the rotor speed once above the natural frequency does not increase the amplitude or the sensitivity of the balancing machine.

Benefits. Because these machines typically run at low speed (200 RPM) the forces on the support systems are low and therefore the balancing machine can be made relatively light and can therefore be made to be transportable. There is consequently less risk to the rotor as is does not have to be transported to the balancing machine.

continued

speed of 1000 RPM and we want a balance grade of G1 then the radial velocity is given by RPMxπ/30 which is 104.7 for our 1000 RPM rotor. To get the eccentricity in µm we divide the velocity grade in mm/s by the radial velocity and multiply by 1000.

i.e. 1/104.7 =0.0095mm or 9.5µm. This same number is also the allowable residual unbalance in gm.mm/kg

What this means is that on a soft bearing balancing machine we can measure the ISO 1940 balance grade directly as we are measuring the “e” value, the accuracy only being affected by the parasitic mass.

It is not possible to determine the balance grade of a machine insitu without carrying out the first 3 steps of a trail weight balance and calculating the balance correction weight. i.e. Initial run, and two trial weight runs (2 plane) and then doing the calculation to determine the balance correction weight.

i.e. you cannot just measure the 1X vibration and make any valid statement regarding the balance grade.

Balance procedure.

Simply carry out a two plane trial weight balance normally and fit the resultant final masses to the rotor.

Checking the sensitivity.

The sensitivity of the soft bearing balancing machine can be checked by calculating the allowable residual mass of the required balance grade for the rotor and adding this mass to the rotor at 0, 120 and 240 degree positions sequentially and running the rotor with the test mass at each position. If the balancing machine is sensitive enough it will be able to determine the position of these test masses in the balance calculation.

i.e. as an example we have a 36 tonne rotor which has an operating speed of 3000 RPM and we wish

to balance to G1 then the allowable mass at the weight radius (750mm) is 76 grams at each end of the rotor (half the ISO allowable each end) The allowable “e” value is 6.4µm p-p. And let us say we have added weight such that the measured motion is 4?µm p-p.

To test the sensitivity we add a weight of 76 grams at 0° and run the rotor and carry out a trim balance calculation based on the previous balance data. The result should ask for the 76 gram weight at 0° to be removed. (or very close to it) do the same with test weight moved to 120°. Again the result should be consistent with the weight move. If not then the sensitivity is not sufficient to accurately balance to this grade.

The above photograph shows a pendulum design soft bearing balancing rig with a 36 tonne rotor spinning at 200 RPM being balanced to within ISO 1940 G1.

The weight limits of this machine are; minimum 4 tonnes and maximum of 36 tonnes. The lower limit is governed by the size of the parasitic mass compared to the rotor which limits the sensitivity, the upper limit by the bearings and roller size and design.

In part 2 we will look at some of the problems encountered with soft bearing balancing machines and we will look at hard bearing balancing machines.

The above photograph shows a pendulum design soft bearing balancing rig with a 36 tonne rotor spinning at 200 RPM being balanced to within ISO 1940 G1. The weight limits of this machine are; minimum 4 tonnes and maximum of 36 tonnes. The lower limit is governed by the size of the parasitic mass compared to the rotor which limits the sensitivity, the upper limit by the bearings and roller size and design. In part 2 we will look at some of the problems encountered with soft bearing balancing machines and we will look at hard bearing balancing machines.

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Predictive Maintenance of Mechanical Failures, using ElectricalMeasurements for Instantaneous Torque. A Modern Approach

Ernesto Wiedenbrug, Ph.D. SM IEEEBaker Instruments - SKF Company

Historically, vibration technology was the only meansavailable to assess many mechanical failures in the field.However, there are conditions in which it is physicallyimpossible to reach proximity to the system in question,being either motor, or the driven load. This example is fromrecent field experience, the new technology’s approach, andthe breakthrough value of the instantaneous torque signalwill give the user a powerful diagnosing tool that can be usedin the in the field.Overall, this new concept of torque signature analysis willallow the user to be capable of identifying looseness,oscillations, cavitations and more, just by looking attorque signatures.

CASE STUDY: CAVITATION

In an industrial application the techniques of monitoringinstantaneous torque at the motor control cabinets,through instantaneous torque signature analysis, madeidentification of a deteriorated submerged pump possible.The accurate load torque estimate of steady stateoperation has been the key tool with which a defectivesubmerged 1,250hp 4,160V pump motor was detected anddiagnosed in a Progress Energy power generation plant.The slow turning pump in question (273rpm, 7ft innerdiameter) showed operation at a torque level of 27%below its two twin systems (23,600Nm vs. 30,400Nm) yetsignificantly higher levels of calculated torque ripple.Figure 1 shows the healthy and faulty torque signatures ofthe pumps side by side.

Figure 1: Healthy (left) and Faulty (right)pump torque signatures.

The defective pump, pulled for repairs, is shown in Fig. 2.The bolts which attach the endbell (Fig. 3) to the pumprusted over time and broke, which caused the endbell tofall 20ft down into the water pit.

Figure 2: Defect 1250hp pump.

Figure 3: Endbell (input funnel) of the pump.

The endbell’s function is to assure laminar water flow,and its loss resulted in increased cavitation with decreasedwater flow.Using the instantaneous torque signal it was possible, forthe first time, to diagnose cavitation of this submergedpump. The instantaneous torque signal is obtainedthrough calculations from the low voltage side of the PTsand CTs of this HV motor and allows a clear diagnosis ofcavitation by predictive maintenance professionals of aremote pump by connecting to low voltage signals.

Predictive Maintenance of Mechanical Failures, using ElectricalMeasurements for Instantaneous Torque. A Modern Approach

Ernesto Wiedenbrug, Ph.D. SM IEEEBaker Instruments - SKF Company

Historically, vibration technology was the only meansavailable to assess many mechanical failures in the field.However, there are conditions in which it is physicallyimpossible to reach proximity to the system in question,being either motor, or the driven load. This example is fromrecent field experience, the new technology’s approach, andthe breakthrough value of the instantaneous torque signalwill give the user a powerful diagnosing tool that can be usedin the in the field.Overall, this new concept of torque signature analysis willallow the user to be capable of identifying looseness,oscillations, cavitations and more, just by looking attorque signatures.

CASE STUDY: CAVITATION

In an industrial application the techniques of monitoringinstantaneous torque at the motor control cabinets,through instantaneous torque signature analysis, madeidentification of a deteriorated submerged pump possible.The accurate load torque estimate of steady stateoperation has been the key tool with which a defectivesubmerged 1,250hp 4,160V pump motor was detected anddiagnosed in a Progress Energy power generation plant.The slow turning pump in question (273rpm, 7ft innerdiameter) showed operation at a torque level of 27%below its two twin systems (23,600Nm vs. 30,400Nm) yetsignificantly higher levels of calculated torque ripple.Figure 1 shows the healthy and faulty torque signatures ofthe pumps side by side.

Figure 1: Healthy (left) and Faulty (right)pump torque signatures.

The defective pump, pulled for repairs, is shown in Fig. 2.The bolts which attach the endbell (Fig. 3) to the pumprusted over time and broke, which caused the endbell tofall 20ft down into the water pit.

Figure 2: Defect 1250hp pump.

Figure 3: Endbell (input funnel) of the pump.

The endbell’s function is to assure laminar water flow,and its loss resulted in increased cavitation with decreasedwater flow.Using the instantaneous torque signal it was possible, forthe first time, to diagnose cavitation of this submergedpump. The instantaneous torque signal is obtainedthrough calculations from the low voltage side of the PTsand CTs of this HV motor and allows a clear diagnosis ofcavitation by predictive maintenance professionals of aremote pump by connecting to low voltage signals.

Predictive Maintenance of Mechanical Failures, using Electrical Measurements for Instantaneous Torque. A Modern Approach

Ernesto Wiedenbrug, Ph.D. SM IEEE Baker Instruments - SKF Company

Historically, vibration technology was the only means available to assess many mechanical failures in the field. However, there are conditions in which it is physically impossible to reach proximity to the system in question, being either motor, or the driven load. This example is from recent field experience, the new technology’s approach, and the breakthrough value of the instantaneous torque signal will give the user a powerful diagnosing tool that can be used in the in the field. Overall, this new concept of torque signature analysis will allow the user to be capable of identifying looseness, oscillations, cavitations and more, just by looking at torque signatures. CASE STUDY: CAVITATION In an industrial application the techniques of monitoring instantaneous torque at the motor control cabinets, through instantaneous torque signature analysis, made identification of a deteriorated submerged pump possible. The accurate load torque estimate of steady state operation has been the key tool with which a defective submerged 1,250hp 4,160V pump motor was detected and diagnosed in a Progress Energy power generation plant. The slow turning pump in question (273rpm, 7ft inner diameter) showed operation at a torque level of 27% below its two twin systems (23,600Nm vs. 30,400Nm) yet significantly higher levels of calculated torque ripple. Figure 1 shows the health y and faulty torque signatures of the pumps side b y side.

Figure 1: Healthy (left) and Faulty (right) pump torque signatures. The defective pump, pulled for repairs, is shown in Fig. 2. The bolts which attach the endbell (Fig. 3) to the pump rusted over time and broke, which caused the endbell to fall 20ft down into the water pit.

Figure 3: Endbell (input funnel) of the pump. The endbell’s function is to assure laminar water flow, and its loss resulted in increased cavitation with decreased water flow. Using the instantaneous torque signal it was possible, for the first time, to diagnose cavitation of this submerged pump. The instantaneous torque signal is obtained through calculations from the low voltage side of the PTs and CTs of this HV motor and allows a clear diagnosis of cavitation b y predictive maintenance professionals of a remote pump by connecting to low voltage signals.

SAFETY AND CONNECTIONS The difference between excellent and poor predictive maintenance programs is frequently the same as an active use of the technology compared to never-again used, dust-covered tools on the shelf. Failure of on-line

continued

predictive maintenance programs can be guaranteed if the instrumentation is not used. On the other hand, success can also be guaranteed if safety, the ease of connection and speed of data acquisition are maximized for tools that give valuable data. The optimal setup for on-line predictive maintenance programs does take this into consideration, and allows for closed-MCC-door testing. Figure [4] show such setups, which have been implemented since the year 2000 in the many hundreds b y various companies, allowing the fast and frequent safe monitoring for their critical motors. The experience that we gained in the last three years shows that the most consistent and active monitoring of critical motors happens in the companies that implemented this safest and fastest setup. The quality of the predictive maintenance program, obviously, depends to a very large extent of the frequency with which the monitoring takes place.

The sensor arrays are mounted inside of the MCC (typically during and outage), and a purely passive port is connected to the front of the cabinet. The connection port is a “dead port” (high impedance) while the instrument is not connected. It turns into a low voltage port of 10V maximal peak-peak voltage only during measurement with the instrument. This setup addresses the latest safety requirements while maximizing data collection speed and ease of use.

CONCLUSIONS Instantaneous torque has been used to identify a multitude of field relevant fault modes. Looseness, cavitation and pumping issues were successfully diagnosed with the time-domain torque signal. Mechanical unbalance and bearing faults can be recognized with the torque vs. frequency representation. Eccentricity can be diagnosed with the demodulated frequency representation of the torque signal. D ynamic VFD applications showing cases of regeneration, dynamic overloading and hunting can also be diagnosed with the time domain signal. Many of these diagnoses are impossible to do successfully using the historic technology of current signature analysis of the motor. The advantages of the modern and proven torque signal were contrasted to the results obtained using the same data if one focused on the current signature analysis. The exact same principals shown with the example of the submerged pump can applied to gearboxes with damaged teeth, suspected broken rotor bars, fans with unbalanced loading as well identifying many other mechanical issues that would impact the torque and loading of the motor. Concerns regarding safe testing are available for safe on.line testing as shown.

BAKER Instruments – an SKF Group Company Study presented b y: Paul Knock

SAFETY AND CONNECTIONS

The difference between excellent and poor predictivemaintenance programs is frequently the same as an activeuse of the technology compared to never-again used, dust-covered tools on the shelf. Failure of on-line predictivemaintenance programs can be guaranteed if theinstrumentation is not used. On the other hand, successcan also be guaranteed if safety, the ease of connectionand speed of data acquisition are maximized for tools thatgive valuable data. The optimal setup for on-linepredictive maintenance programs does take this intoconsideration, and allows for closed-MCC-door testing.Figure [4] show such setups, which have beenimplemented since the year 2000 in the many hundreds byvarious companies, allowing the fast and frequent safemonitoring for their critical motors. The experience thatwe gained in the last three years shows that the mostconsistent and active monitoring of critical motorshappens in the companies that implemented this safestand fastest setup. The quality of the predictivemaintenance program, obviously, depends to a very largeextent of the frequency with which the monitoring takesplace.

Figure 4: Safe connection with EP box.

The sensor arrays are mounted inside of the MCC(typically during and outage), and a purely passive port isconnected to the front of the cabinet. The connection portis a “dead port” (high impedance) while the instrument isnot connected. It turns into a low voltage port of 10Vmaximal peak-peak voltage only during measurementwith the instrument. This setup addresses the latest safetyrequirements while maximizing data collection speed andease of use.

CONCLUSIONS

Instantaneous torque has been used to identify a multitudeof field relevant fault modes. Looseness, cavitation andpumping issues were successfully diagnosed with thetime-domain torque signal. Mechanical unbalance andbearing faults can be recognized with the torque vs.frequency representation. Eccentricity can be diagnosedwith the demodulated frequency representation of thetorque signal. Dynamic VFD applications showing casesof regeneration, dynamic overloading and hunting canalso be diagnosed with the time domain signal.Many of these diagnoses are impossible to do successfullyusing the historic technology of current signature analysisof the motor. The advantages of the modern and proventorque signal were contrasted to the results obtained usingthe same data if one focused on the current signatureanalysis. The exact same principals shown with theexample of the submerged pump can applied to gearboxeswith damaged teeth, suspected broken rotor bars, fanswith unbalanced loading as well identifying many othermechanical issues that would impact the torque andloading of the motor.Concerns regarding safe testing are available for safe on-line testing as shown.

Figure 5: Explorer unit with EP2 panel interface.

BAKER Instruments –an SKF Group Company

Study presented by: Paul Knock

SAFETY AND CONNECTIONS

The difference between excellent and poor predictivemaintenance programs is frequently the same as an activeuse of the technology compared to never-again used, dust-covered tools on the shelf. Failure of on-line predictivemaintenance programs can be guaranteed if theinstrumentation is not used. On the other hand, successcan also be guaranteed if safety, the ease of connectionand speed of data acquisition are maximized for tools thatgive valuable data. The optimal setup for on-linepredictive maintenance programs does take this intoconsideration, and allows for closed-MCC-door testing.Figure [4] show such setups, which have beenimplemented since the year 2000 in the many hundreds byvarious companies, allowing the fast and frequent safemonitoring for their critical motors. The experience thatwe gained in the last three years shows that the mostconsistent and active monitoring of critical motorshappens in the companies that implemented this safestand fastest setup. The quality of the predictivemaintenance program, obviously, depends to a very largeextent of the frequency with which the monitoring takesplace.

Figure 4: Safe connection with EP box.

The sensor arrays are mounted inside of the MCC(typically during and outage), and a purely passive port isconnected to the front of the cabinet. The connection portis a “dead port” (high impedance) while the instrument isnot connected. It turns into a low voltage port of 10Vmaximal peak-peak voltage only during measurementwith the instrument. This setup addresses the latest safetyrequirements while maximizing data collection speed andease of use.

CONCLUSIONS

Instantaneous torque has been used to identify a multitudeof field relevant fault modes. Looseness, cavitation andpumping issues were successfully diagnosed with thetime-domain torque signal. Mechanical unbalance andbearing faults can be recognized with the torque vs.frequency representation. Eccentricity can be diagnosedwith the demodulated frequency representation of thetorque signal. Dynamic VFD applications showing casesof regeneration, dynamic overloading and hunting canalso be diagnosed with the time domain signal.Many of these diagnoses are impossible to do successfullyusing the historic technology of current signature analysisof the motor. The advantages of the modern and proventorque signal were contrasted to the results obtained usingthe same data if one focused on the current signatureanalysis. The exact same principals shown with theexample of the submerged pump can applied to gearboxeswith damaged teeth, suspected broken rotor bars, fanswith unbalanced loading as well identifying many othermechanical issues that would impact the torque andloading of the motor.Concerns regarding safe testing are available for safe on-line testing as shown.

Figure 5: Explorer unit with EP2 panel interface.

BAKER Instruments –an SKF Group Company

Study presented by: Paul Knock

Machinery Health Analyser – Stay Current Program

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Contact your local sales team today!Australia1300 553 051 [email protected]

New Zealand(09) 441 [email protected]

For further information or to secure your position please contact our conference team,

Leanne on +64 9 296 1333 or Glen on +64 21 897 547.

You can email us at [email protected] www.vanz.org.nz

Designed by Flashpoint Design & Marketing

Practical Solutions for Reliability Improvement

VANZconference2015

26th Annual Conference. May 26th, 27th and 28th.

Wairakei Resort, Taupo, New Zealand

www.vanz.org.nz

The Awareness Day will run in a new format this year, there will be hands on sessions where you can see live demonstrations and have a go with Condition Monitoring techniques you may be unfamiliar with. These sessions will be running throughout the day so small groups can attend each station giving adequate opportunity for each person to ask questions and try various techniques.

Awareness Day - Hands On!

Main Conference

Speakers 2015

New

Format!!

Technique

Introduction to Vibration and Plant ReliabilityInfrared ThermographyLubrication - Oil / Wear Debris Analysis and Lubrication Management Vibration - How it works and transducer selectionAlignment - Introduction to Laser AlignmentBalancing - Introduction to Static, Dynamic and Mode shapes.Electric Motors - Condition Monitoring of windings.Ultrasonic-Electrical inspection/leak detectionNon Destructive Testing - Crack and Flaw detection methodsFitting a Mechanical sealResonance - Causes and Remedies

Presenter(s)

Jason Tranter, (Main Hall)Tom Aldridge Cameron Blackbourn & Chris Unsworth Nathan Osborn, John Lawrence, Barry Shaw Chris O’Leary Derek Krippner Mike Davis & Bill van den Hoven James NealeDave Byron & Mark Peacock Will DaleSimon Hurricks

Abstracts and speaker bios will be uploaded to our website - www.vanz.org.nz Our website is being updated regularly as

abstracts come to hand.

Bob CraftBob CraftSimon Hurricks Tony Hardcastle Matt BlanchTom MisaMaurice Perry Jason Tranter Chris JamesMike Davis Howard Bosely William LiuGlen Pepper Cameron Blackbourn James NealeBhavin Desai

GE - Int KeynoteGE - Int KeynoteGensisBallanceNobel Engineering Contact EnergyPartnered ResultsMobiusSKFMachine MonitorCHH (Retired)SGSGenesis EnergyTasman Reliability Solutions Waikato University National Instruments

Moving from Predictive to Proactive Condition Monitoring and Evaluation Data Compartmentalization and StatisticsResonance That Bites"The significance of the insignificant"Taking notice to changeFailure in Hot Well PumpsPump Station Case StudyOrbits, centerline plots, and rotor dynamicsSlow Speed Vibration MonitoringElectrical MachinesAre you missing significant value from your VA Program?Bearing failure from high frequency electricityRCA of a Bearing FailureNew Oil Types and VarnishingTechnological Convergence & the role of Big DataLarge Scale Deployment of Online Condition Monitoring in a US Based Utilities Company

Day 1 Wednesday 27 May 2015

08:00 00:30 08:30 Registration TEA & COFFEE PROVIDED 08:30 00:20 08:50 Cameron Blackbourn VANZ

president Conference opening & Key Sponsor address - Commtest / NVMS

08:50 01:00 09:50 Opening Keynote: Bob Craft, GE, Moving from Predictive to Proactive Condition Monitoring and Evaluation

09:50 00:20 10:10 Exhibitor Introductions Short overview of new products and services and prize draw per Exhibitor / Trade Stand

10:10 00:30 10:40 Break Morning Tea

10:40 00:30 11:10 Simon Hurricks: Resonance, the vibration that bites

11:10 00:30 11:40 Howard Bosley - What Your VA Program Has Been Missing

11:40 00:30 12:10 Mike Davis - Electrical Case Study.

12:10 01:20 13:30 Break Lunch

13:30 00:45 14:15 Jason Tranter - Orbits, centerline plots, and rotor dynamics

14:15 00:45 15:00 Chris James - Slow speed vibration monitoring

15:00 00:40 15:40 Break Afternoon Tea 15:40 00:40 16:20 Matt Blanch: Taking notice of change 16:20 00:40 17:00 Roundtable Discussion 17:00 01:30 18:30 Networking - Refreshments and Canapés in Exhibitor Area 18:30 23:00 Dinner and Entertainment

0.31

Day 2 Thursday 28 May 2015 08:00 00:30 08:30 Registration TEA & COFFEE PROVIDED 08:30 01:00 09:30 Keynote: Bob Craft: Data Compartmentalization and Statistics 09:30 00:40 10:10 AGM - VANZ Open to all to attend, especially those who want to contribute to the future growth and prosperity of VANZ

10:10 00:30 10:40 Break Morning Tea

10:40 00:20 11:00 Tony Hardcastle: "The significance of the insignifiant"

11:00 00:20 11:20 William Liu - Bearing failure from high frequency electricity

11:20 00:40 12:00 Cameron Blackbourn - New problems, New Solutions. Identification and Rectifaction of Varnish in Oil Systems

12:00 01:20 13:20 Break Lunch

13:20 00:20 13:40 Bhavin Desai - Large Scale Deployment of Online Condition Monitoring 13:40 00:20 14:00 Tom Misa - Failure in hot well pumps

14:00 00:40 14:40 Maurice Perry: Pump Sation Case Study

14:40 00:20 15:00 Break Afternoon Tea 15:00 00:40 15:40 James Neale: Technological Convergence and the role of Big Data 15:40 00:10 15:50 Alexander Brozeit - Case Study, Non Standard Vibration Analysis.

15:50 00:20 16:10 President closing address Awards and Vendor Prize Draws - remember you must be there to collect them...

Please note: Times may be subject to change

Conference timetable

New Zealand Contact: James Neale Mob: 027 2555 659 o�[email protected]

EagleBurgmann Australasia Pty Ltd (NZ)PO Box 300858, Albany, Auckland 0752, 47 William Pickering Drive, Rosedale, Auckland 0632Ph: +64 (0)9 448 5001, Fax: +64 (0)9 415 0599, Email: [email protected]

● Mechanical Seals ● Cartridge Seals ● Seal Supply Systems ● Gland Packing● Static—Sheet Jointing / Formed Gaskets● Expansion Joints—Fabric / Rubber / Metal● Bearing Isolators ● Current Diverter Rings ● Couplings—Diaphragm / Magnetic● Marine Seals ● MECO Seals ● Dry Powder Seals● Segmented Carbon Rings

Made to meet your need,but exceed your expectations

Evolving Reliability at Penrose Mill

by Craig Allan

This paper describes some of the “tools” and varied experiences in improving the reliability at the Carter Holt Harvey Penrose Mill over the last ten years. It is crudely divided into a section of the practises we use and a number of case studies where we have endeavoured to improve.

The Carter Holt Harvey Penrose Mill Plant was started up in 1982 producing 100% recycled medium to manufacture cardboard boxes from waste paper collected in and around Auckland. The Original (1982) specification was for 30,000 tonnes per year and a maximum speed of 350

metres/min. In 1988 the machine underwent a major rebuild where a second former was added and the press arrangement was improved, with the output specification being 60,000 tonnes per year and a max speed of 650 metres/min. Since then there have been many minor upgrades around the machine to improve production and currently the paper machine produces around 80,000 tonnes per year and has a maximum speed of 760 metres/min.

Like any paper mill production is 24/7, approximately 360 days per year and the product


This paper describes some of the “tools” and varied experiences in improving the reliability at the Carter Holt Harvey Penrose Mill over the last ten years. It is crudely divided into a section of the practises we use and a number of case studies where we have endeavoured to improve. The Carter Holt Harvey Penrose Mill Plant was started up in 1982 producing 100% recycled medium to manufacture cardboard boxes from waste paper collected in and around Auckland. The Original (1982) specification was for 30,000 tonnes per year and a maximum speed of 350 metres/min. In 1988 the machine underwent a major rebuild where a second former was added and the press arrangement was improved, with the output specification being 60,000 tonnes per year and a max speed of 650 metres/min. Since then there have been many minor upgrades around the machine to improve production and currently the paper machine produces around 80,000 tonnes per year and has a maximum speed of 760 metres/min.

Figure 1: Penrose Mill Paper Machine


This paper describes some of the “tools” and varied experiences in improving the reliability at the Carter Holt Harvey Penrose Mill over the last ten years. It is crudely divided into a section of the practises we use and a number of case studies where we have endeavoured to improve. The Carter Holt Harvey Penrose Mill Plant was started up in 1982 producing 100% recycled medium to manufacture cardboard boxes from waste paper collected in and around Auckland. The Original (1982) specification was for 30,000 tonnes per year and a maximum speed of 350 metres/min. In 1988 the machine underwent a major rebuild where a second former was added and the press arrangement was improved, with the output specification being 60,000 tonnes per year and a max speed of 650 metres/min. Since then there have been many minor upgrades around the machine to improve production and currently the paper machine produces around 80,000 tonnes per year and has a maximum speed of 760 metres/min.



continued

is sold about 60% to Australasia with the remainder being exported to mainly Asia and USA.

The core Maintenance team is in-house and specialist services eg. VA & Thermographic “experts” are contracted in. While Penrose Mill has limited expertise on-site, we do not have the expertise or experience of the contractors who are dealing with these technologies continuously. Shut labour (trades people) is also contracted in for plant shutdown work. Each production shift has a shift fitter & electrician attached to attend to maintenance and PM work. The Mill is lucky to have a well experienced maintenance team with engineers, the foremen and a number of tradesmen having been working in the Mill since it started.

The Maintenance downtime target is 3% including monthly planned shuts, but excluding 7 day annual shut. Last year it was 3.2%, (Mech: 0.76%, Elect: 0.48%, Inst: 0.02%). The maintenance downtime trend has been reasonably static for the last ten years, but as the paper machine and associated plant has been steadily improved, uptime and production for the

whole plant has steadily improved.

Maintenance Tools

The OEM manuals & documentation for the Mill are good and are being continuously updated. A CMM System isn’t a cure-all but it can help. At Penrose Mill we use SAP now, but we used to use an old mainframe system. The Maintenance Plans were heavily time-based, and a lot still are, but we are moving away from these where possible and practical. The Maintenance plans are also continuously being updated with more detail as the trades skills change. All the maintenance plans were reviewed two years ago by the engineers and leading hands and aligned with reality and requirements. The BOMS were hopelessly inaccurate after transfer into SAP, as a result of a data mismatch in the migration to SAP. It took one of our Engineers about a year to tidy up the mess that we were left with. The old adage of “Garbage In-Garbage Out” is true. Having accurate data is important when maintaining stores and spares (and uptime).

We experience a number of “problems” with our SAP system. It is Inflexible, so we sometimes need

Figure 2: Penrose Mill Downtime Graph

Like any paper mill production is 24/7, approximately 360 days per year and the product is sold about 60% to Australasia with the remainder being exported to mainly Asia and USA. The core Maintenance team is in-house and specialist services eg. VA & Thermographic “experts” are contracted in. While Penrose Mill has limited expertise on-site, we do not have the expertise or experience of the contractors who are dealing with these technologies continuously. Shut labour (trades people) is also contracted in for plant shutdown work. Each production shift has a shift fitter & electrician attached to attend to maintenance and PM work. The Mill is lucky to have a well experienced maintenance team with engineers, the foremen and a number of tradesmen having been working in the Mill since it started.

The Maintenance downtime target is 3% including monthly planned shuts, but excluding 7 day annual shut. Last year it was 3.2%, (Mech: 0.76%, Elect: 0.48%, Inst: 0.02%). The maintenance downtime trend has been reasonably static for the last ten years, but as the paper machine and associated plant has been steadily improved, uptime and production for the whole plant has steadily improved. Maintenance Tools The OEM manuals & documentation for the Mill are good and are being continuously updated. A CMM System isn’t a cure-all but it can help. At Penrose Mill we use SAP now, but we used to use an old mainframe system. The Maintenance Plans were heavily time-based, and a lot still are, but we are moving away from these where possible and practical. The Maintenance plans are also continuously being updated with more detail as the trades skills change. All the maintenance plans were reviewed two years ago by the engineers and leading hands and aligned with reality and requirements. The BOMS were

Penrose Mill: Downtime

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1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009

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Figure 2: Penrose Mill Downtime Graph

continued

to do work-arounds, however these developments are expensive and it seems to be difficult to get them. We often hear “That feature is in the later version”.

In our old version of SAP we have paid for a limited ability to handle Microsoft Word Documents and we use this feature to store important maintenance information. (Our system doesn’t presently handle pdf files).

As part of a maintenance team, history is important. We want to know the last time we fixed a particular plant item, what we did, what we used, and who we bought parts off. A great scheme to reduce our IT bill was to archiving our history – so it is difficult and therefore impractical to retrieve this information, historical data is critical for good maintenance.

Corporate Initiatives can “help” keep us busy

A number of years ago a stores optimisation was done at a corporate level without consultation with the sites and affected people, ie. engineers and fitters and the designation of the spherical roller bearings was changed from metallic cages to polyamide cages. Spherical roller bearings are used in our dryer screen rolls amongst other places and saved perhaps $10- per bearing. After a major bearing failure in the paper machine, we found no cage debris, which lead us to question

the cages. Unfortunately Polyamide cages are incompatible with the high temperature synthetic oil used in the paper machine. We now do not have any bearings with polyamide cages on-site.

The cost of this saving was quite a bit, not including the several lots of crash downtime, and subsequent repairs, we spent about $20k each in two annual shutdowns removing all the bearing caps and checking the cages and replacing the poly-cage bearings.

Work Order Backlog.

We do Regular reviews of the work order backlog to get rid of the dead wood. Far too often duplicate work orders are entered in the system. Also every morning at an operations meeting the operational issues and notifications and work orders created since the last meeting are reviewed. Recurring problems can be identified that might otherwise be missed by the individual shifts, because of the roster that they are on. The following busy graph shows a steadily improving reducing backlog of both planned maintenance and other maintenance work orders. This is due to several things, 1) the major “tidy-up” and alignment of the maintenance plans and 2) the improvement in maintenance means we don’t go back to fix the same problem all the time.

BACKLOG

0

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1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 51

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2005 TOT BACKLOG

2005 REG.MAINT

2006 TOT BACKLOG

2006 REG.MAINT

2007 TOT BACKLOG

2007 REG.MAINT

2008 TOT BACKLOG

2008 REG.MAINT

2009 TOT BACKLOG

2009 REG.MAINT

Shuts and Planning We now have approximately ten 14 hour shuts per year and one major annual seven day shut. (We used to shut every three weeks!). These shuts are scheduled up to a year in advance so we can book in contractors and experts from overseas – although they can move if necessary. Planning is done rigorously to avoid clashes – for example sparkies and fitters wanting the same bit of plant to work on or with. As staff have changed the shut organisation has changed – we now have more supervisors and more accurate work instructions. Critical Spares We capitalise or purchase critical spares as required, eg. a Pulper Bearing Cartridge was purchased so that this critical item can be rebuilt in a controlled manner with precise tolerances and therefore reduces downtime. Tools can make your work much safer and faster, as well as reduce downtime. Where it can be justified we buy or make tools as required to get the job done properly. Some critical examples for our plant are an induction heater, hydraulic nuts and axial displacement tools for bearing fitting. Bearing Fitting Bearing fitting is key training for all maintenance staff, including electricians. We found that bearing failures on electric motors decreased when the correct training was given. For all large spherical roller bearings the axial displacement method of fitting is used, and for smaller bearings the clearances are measured on assembly where appropriate. Bearing related downtime is generally low (~0.25%). The trendline graph shows the effect of a one Winder Rider Roll bearing failure in 2006 (the dot shows where it would have been except for this).

Figure 3: Penrose Mill Work Order Backlog Graph Figure 3: Penrose Mill Work Order Backlog Graph

continued

Shuts and Planning

We now have approximately ten 14 hour shuts per year and one major annual seven day shut. (We used to shut every three weeks!). These shuts are scheduled up to a year in advance so we can book in contractors and experts from overseas – although they can move if necessary. Planning is done rigorously to avoid clashes – for example sparkies and fitters wanting the same bit of plant to work on or with. As staff have changed the shut organisation has changed – we now have more supervisors and more accurate work instructions.

Critical Spares

We capitalise or purchase critical spares as required, eg. a Pulper Bearing Cartridge was purchased so that this critical item can be rebuilt in a controlled manner with precise tolerances and therefore reduces downtime.

Tools can make your work much safer and faster, as well as reduce downtime. Where it can be justified we buy or make tools as required to get the job done properly. Some critical examples for our plant are an induction heater, hydraulic nuts and axial displacement tools for bearing fitting.

Bearing Fitting

Bearing fitting is key training for all maintenance staff, including electricians. We found that bearing failures on electric motors decreased when the correct training was given. For all large spherical roller bearings the axial displacement method of fitting is used, and for smaller bearings the clearances are measured on assembly where appropriate.

Bearing related downtime is generally low (~0.25%). The trendline graph shows the effect of a one Winder Rider Roll bearing failure in 2006 (the dot shows where it would have been except for this).

Alignment

Laser alignment is used for all rotating machinery where possible and the results can be seen in VA. We also use laser alignment & sonic tension meter for V-belts. We used to change most v-belts annually, but we now inspect these belts annually and change if required. We saved about $2000 each (materials & labour) for our 5 vacuum pumps and have not suffered any additional significant downtime. We have found issues with “set-free” belts being within the

Bearing Failure Hours

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20

30

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1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009

Year

Hou

rs/y

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Figure 4: Penrose Mill: Bearing Related Downtime Alignment Laser alignment is used for all rotating machinery where possible and the results can be seen in VA. We also use laser alignment & sonic tension meter for V-belts. We used to change most v-belts annually, but we now inspect these belts annually and change if required. We saved about $2000 each (materials & labour) for our 5 vacuum pumps and have not suffered any additional significant downtime. We have found issues with “set-free” belts being within the manufacturer tolerance, but not suitable for precision maintenance or optimal operation Balancing Following presentations at a reliability workshop run by CHH and also at VANZ ISO 1940 G1.0 is the standard for all our rotating machinery. Our balancing supplier doesn't question this. We have had to be careful with the supply of v-belt Pulleys which are typically G6.3. Better than original balancing means that the paper machine can run faster and make more paper with less wear and tear. Vibration Analysis VA at Penrose Mill was originally done using a HP Spectrum Analyser on a "tea-trolley" and CHH purchased an Entek datapac 1250 to keep up with CHH Whakatane. The program was fairly light, with the paper machine rolls being done and a couple of other critical plant items. A decision was made to jump in “boots and all” and all the plant data for the motors above 11kW, (an arbitrary choice), was detailed along with relevant plant data like bearings, pulley sizes, number of pump vanes and so on. The routes were split up on logical paths and a collection frequency assigned. Since then more items have been added and a number of collection frequencies have been "adjusted"

Figure 4: Penrose Mill: Bearing Related Downtime

continued

manufacturer tolerance, but not suitable for precision maintenance or optimal operation

Balancing

Following presentations at a reliability workshop run by CHH and also at VANZ

ISO 1940 G1.0 is the standard for all our rotating machinery. Our balancing supplier doesn’t question this. We have had to be careful with the supply of v-belt Pulleys which are typically G6.3. Better than original balancing means that the paper machine can run faster and make more paper with less wear and tear.

Vibration Analysis

VA at Penrose Mill was originally done using a HP Spectrum Analyser on a “tea-trolley” and CHH purchased an Entek datapac 1250 to keep up with CHH Whakatane. The program was fairly light, with the paper machine rolls being done and a couple of other critical plant items. A decision was made to jump in “boots and all” and all the plant data for the motors above 11kW, (an arbitrary choice), was detailed along with relevant plant data like bearings, pulley sizes, number of pump vanes and so on.

The routes were split up on logical paths and a collection frequency assigned. Since then more items have been added and a number of collection frequencies have been “adjusted” based on plant usage and requirements. This expertise is contracted in from a reliability engineering co. We get a verbal report before the technician leaves site and this is followed up by a written report within 7 days with priorities for action. Following review

of the report work orders are created in SAP for action (and records). The loop is not fully closed yet – getting what we found back to VA team (we’re working on it!)

Thermographic Checks

“In the old days” fitters (and sparkies) had a great mechanical sympathy for plant and would use the basic senses: see, smell, touch, hear but as times and tradesmen have changed this has been lost.

To get around this and get our people out around the plant we prescribe a temperature check route for both electricians and fitters using a $300 temperature gun. It isn’t half as good as an IR camera, but in the current economic climate it is hard for our small Mill to justify the cost of the better tools, even though they would be most useful for process troubleshooting and much more.

Bearing temperature routes are graphed and exception points are investigated. We used to do this in SAP, but as mentioned earlier the system is inflexible and plant temperature graphs are far better handled in Excel.

We also use a specialist contractor to come into the Mill regularly and check critical items such as switchgear.

based on plant usage and requirements. This expertise is contracted in from a reliability engineering co. We get a verbal report before the technician leaves site and this is followed up by a written report within 7 days with priorities for action. Following review of the report work orders are created in SAP for action (and records). The loop is not fully closed yet – getting what we found back to VA team (we’re working on it!) Thermographic Checks "In the old days" fitters (and sparkies) had a great mechanical sympathy for plant and would use the basic senses: see, smell, touch, hear but as times and tradesmen have changed this has been lost. To get around this and get our people out around the plant we prescribe a temperature check route for both electricians and fitters using a $300 temperature gun. It isn't half as good as an IR camera, but in the current economic climate it is hard for our small Mill to justify the cost of the better tools, even though they would be most useful for process troubleshooting and much more. Bearing temperature routes are graphed and exception points are investigated. We used to do this in SAP, but as mentioned earlier the system is inflexible and plant temperature graphs are far better handled in Excel. We also use a specialist contractor to come into the Mill regularly and check critical items such as switchgear.

Figure 5: A Typical Temperature Graph Lubrication & Oil Analysis All the lubrication on site is done by our own lubrication technician. We have had a full Lube schedule for a number of years. The Lube technician has just been through updating this versus actual practice. Our lube supplier is actively involved in the selection of lubricants and any lubricant changes are researched and discussed fully and are logged in

Figure 5: A Typical Temperature Graph continued

Lubrication & Oil Analysis

All the lubrication on site is done by our own lubrication technician. We have had a full Lube schedule for a number of years. The Lube technician has just been through updating this versus actual practice. Our lube supplier is actively involved in the selection of lubricants and any lubricant changes are researched and discussed fully and are logged in the lube database with who requested why & and when. Oil samples for critical plant are taken on a regular schedule and analysed by Mobil for us.

Failure Analysis

This is a matter of course for all downtime greater than 90 minutes or anything less than that which is deemed critical. Suppliers and the OEM are involved with these investigations and often have lead to improvements in our plant, (some examples follow).

Redesign is not uncommon and is done with the help of the leading hands, OEMs and also local experts from companies such as FAG, Mobil & Inspyer. We regularly review our top 20 Functional Locations, by expense and by number of work orders based on a report from SAP and review which ones can be improved.

Plant Improvements.

The following are a number of examples of improvements we have made in our plant (along with a couple of “works-in-progress”).

Pulper rotors

All the waste paper, (and other assorted rubbish including engine blocks, chairs and dumb-bells), coming into the Mill is pulped up in a Main Pulper. The main element in this is a large stainless steel rotor. This rotor used to last a variable amount of time - but as the years went by it seemed to be getting less and less. We were rebuilding them to a good standard locally using a specialist welding company and stellite

hard-facing. Eventually the changes got down to 1-2 months - and every rebuild seemed to cost $12000 plus the change time. We purchased a brand new rotor from the OEM and compared our best efforts with theirs and found that we were not rebuilding back to the correct dimensions. Since we have drawn up the correct rebuild quality, we are getting much longer life and better pulping results – and therefore increased production

Figure 6: Main Pulper Rotor

Similarly a “Fiberizer” (a secondary pulper attached to the main pulper) was costing about $65k per year and approx. 50 work orders per year (~one a week) due to poor throughput and overloads. We reviewed the plant item, asked the OEM about wear and any improvements, and following this we purchased some updated design screenplates and rotors.

The screenplates were great, at least twice as good as the previous design, but the rotors were useless and wore out or broke after 1-4 weeks. We went back to an original design rotor modified by our Mechanical Foreman which worked better. We talked about the rotors with the OEM (Voith) and then following much discussion they supplied a new rotor as per the original design. Now the machine works much better, with rotor changes about every 70 days instead of every month. The rotor is rebuilt to the OEM dimensions every time it is removed at a

the lube database with who requested why & and when. Oil samples for critical plant are taken on a regular schedule and analysed by Mobil for us. Failure Analysis This is a matter of course for all downtime greater than 90 minutes or anything less than that which is deemed critical. Suppliers and the OEM are involved with these investigations and often have lead to improvements in our plant, (some examples follow). Redesign is not uncommon and is done with the help of the leading hands, OEMs and also local experts from companies such as FAG, Mobil & Inspyer. We regularly review our top 20 Functional Locations, by expense and by number of work orders based on a report from SAP and review which ones can be improved. Plant Improvements. The following are a number of examples of improvements we have made in our plant (along with a couple of “works-in-progress”). Pulper rotors All the waste paper, (and other assorted rubbish including engine blocks, chairs and dumb-bells), coming into the Mill is pulped up in a Main Pulper. The main element in this is a large stainless steel rotor. This rotor used to last a variable amount of time - but as the years went by it seemed to be getting less and less. We were rebuilding them to a good standard locally using a specialist welding company and stellite hard-facing. Eventually the changes got down to 1-2 months - and every rebuild seemed to cost $12000 plus the change time. We purchased a brand new rotor from the OEM and compared our best efforts with theirs and found that we were not rebuilding back to the correct dimensions. Since we have drawn up the correct rebuild quality, we are getting much longer life and better pulping results – and therefore increased production

Figure 6: Main Pulper Rotor

continued

cost of about $3400, so reducing the number of rotor changes saves money.

Roof exhaust fans

Paper Machines generate a lot of water vapour and in 2000 we upgraded the Paper machine hall ventilation to save us having to replace all the purlins and fittings (about $500k) every five years. Part of the upgrade was to install new ceiling exhaust fans.

These fans were built by a local company and could have been better:

• The motor is installed out of the airflow (good)

• the v-belts, pulleys and bearings are inside an aluminium housing (good)

• but there is no floating bearing on the assembly (not so good)

• although the mounting plates were flimsy enough to allow a bearing to float & after a while they fatigued allowing the bearing to really float. (not so good either)

After a number of failures we decided to redesign and replace the individual P209 flanged bearing housings with a custom VRE-type bearing cartridge fitted with bearing isolators. Since then these problems have reduced to zero.

We also found that the tolerances of manufacture are less than we require, so we bore the fan hubs, and we reinforce the fan casings ourselves.

Drying Cylinder Front Side Bearing

Failures

The Paper Machine has a dryer section where the paper is dried from about 50% water to about 92% water using both steam heated cylinders (about 130 deg.C) and heated air. This part of the Paper Machine has a circulating lube oil system with Mobil SHCPM synthetic oil. The drying cylinder floating bearings were fitted with N3040K cylindrical roller bearings which are progressively being replaced with FAG self aligning cylindrical roller (SACR) bearings.

Following a number of failures we started a failure analysis and talked to the OEM machine supplier (Voith), our bearing supplier (FAG) and our oil supplier (Mobil). We investigated the expected bearing life (the paper machine was 20 years old and the speed had doubled), the oil viscosity (Voith recommended an increase from ISO VG150 to 220 which we have done), oil flows (Voith also recommended an increase, but we have not followed through on this yet), and operating temperature inside the paper machine hood. Inspection of the bearings with FAG and Inspyer also showed a stationary etch corrosion failure mechanism. Following this, we capitalised the purchase of an oil purifier and an oil humidity monitor and since then our failures have decreased. We also use this purifier in other hydraulic and lubrication stations around the Mill when the humidity levels reach an alarm point.

Winder Rider Roll Bearings

The paper that is made in our paper machine is

Similarly a "Fiberizer" (a secondary pulper attached to the main pulper) was costing about $65k per year and approx. 50 work orders per year (~one a week) due to poor throughput and overloads. We reviewed the plant item, asked the OEM about wear and any improvements, and following this we purchased some updated design screenplates and rotors. The screenplates were great, at least twice as good as the previous design, but the rotors were useless and wore out or broke after 1-4 weeks. We went back to an original design rotor modified by our Mechanical Foreman which worked better. We talked about the rotors with the OEM (Voith) and then following much discussion they supplied a new rotor as per the original design. Now the machine works much better, with rotor changes about every 70 days instead of every month. The rotor is rebuilt to the OEM dimensions every time it is removed at a cost of about $3400, so reducing the number of rotor changes saves money. Roof exhaust fans Paper Machines generate a lot of water vapour and in 2000 we upgraded the Paper machine hall ventilation to save us having to replace all the purlins and fittings (about $500k) every five years. Part of the upgrade was to install new ceiling exhaust fans. These fans were built by a local company and could have been better:

• The motor is installed out of the airflow (good) • the v-belts, pulleys and bearings are inside an

aluminium housing (good) • but there is no floating bearing on the assembly (not

so good) • although the mounting plates were flimsy enough to

allow a bearing to float & after a while they fatigued allowing the bearing to really float. (not so good either)

After a number of failures we decided to redesign and replace the individual P209 flanged bearing housings with a custom VRE-type bearing cartridge fitted with bearing isolators. Since then these problems have reduced to zero. We also found that the tolerances of manufacture are less than we require, so we bore the fan hubs, and we reinforce the fan casings ourselves. Drying Cylinder Front Side Bearing Failures The Paper Machine has a dryer section where the paper is dried from about 50% water to about 92% water using both steam heated cylinders (about 130 deg.C) and heated air. This part of the Paper Machine has a circulating lube oil system with Mobil SHCPM

Figure 7: Roof Exhaust Fan Figure 7: Roof Exhaust Fancontinued

rewound to specified sizes and widths for our customers. Part of the Winder is a “Rider Roll” which runs on the top of the reels to ensure accurately controlled density and tension in the reels for the customer.

In 2007 we started having bearing problems with the rider roll on the Winder. The failure looked like a lubrication failure, as the cage was worn so much that the rollers turned and acted as a large brake - welding the inner race to the shaft. 43 hours later the machine was going again, (after the shaft had been welded up, because the bearing race had to be cut off and the shaft had to be straightened because it was bent from the welding).

The only changes noted were that we had overhauled the roll in 2003 and 2004 with a German OEM serviceman, and also changed to better grease, for this location (the outer ring is rotating - spinning up from zero to 1800 rpm & then back down to zero every nine minutes)

In April 2007 we experienced another failure, and following discussions with our bearing supplier, we decided to upgrade the grease to an even better grease which we use in other small roll outer-ring-rotating applications on-site. We had

bought a spare shaft at this stage so the repairs took a lot less time and we were better at it - not that we wanted to be good at replacing it!

Then in August 2007 a further failure occurred

synthetic oil. The drying cylinder floating bearings were fitted with N3040K cylindrical roller bearings which are progressively being replaced with FAG self aligning cylindrical roller (SACR) bearings. Following a number of failures we started a failure analysis and talked to the OEM machine supplier (Voith), our bearing supplier (FAG) and our oil supplier (Mobil). We investigated the expected bearing life (the paper machine was 20 years old and the speed had doubled), the oil viscosity (Voith recommended an increase from ISO VG150 to 220 which we have done), oil flows (Voith also recommended an increase, but we have not followed through on this yet), and operating temperature inside the paper machine hood. Inspection of the bearings with FAG and Inspyer also showed a stationary etch corrosion failure mechanism. Following this, we capitalised the purchase of an oil purifier and an oil humidity monitor and since then our failures have decreased. We also use this purifier in other hydraulic and lubrication stations around the Mill when the humidity levels reach an alarm point.

Dryer Cylinder Bearing Replacements

-12345678910

2001 2002 2003 2004 2005 2006 2007 2008 2009 2010

Year

No. o

f Bea

rings

repl

aced

Figure 8: Dryer Cylinder Bearing Replacements Figure 8: Dryer Cylinder Bearing Replacements

Winder Rider Roll Bearings The paper that is made in our paper machine is rewound to specified sizes and widths for our customers. Part of the Winder is a “Rider Roll” which runs on the top of the reels to ensure accurately controlled density and tension in the reels for the customer.

In 2007 we started having bearing problems with the rider roll on the Winder. The failure looked like a lubrication failure, as the cage was worn so much that the rollers turned and acted as a large brake - welding the inner race to the shaft. 43 hours later the machine was going again, (after the shaft had been welded up, because the bearing race had to be cut off and the shaft had to be straightened because it was bent from the welding). The only changes noted were that we had overhauled the roll in 2003 and 2004 with a German OEM serviceman, and also changed to better grease, for this location (the outer ring is rotating - spinning up from zero to 1800 rpm & then back down to zero every nine minutes) In April 2007 we experienced another failure, and following discussions with our bearing supplier, we decided to upgrade the grease to an even better grease which we use in other small roll outer-ring-rotating applications on-site. We had bought a spare shaft at this stage so the repairs took a lot less time and we were better at it - not that we wanted to be good at replacing it! Then in August 2007 a further failure occurred - still the same failure mechanism - cage failure then the rollers turning. Finally we decided to go back to the original "basic" grease. The failures appear to have stopped. By then we had also capexed a new Rider Roll (About EUR 40k) and have recently installed it. What did we learn? Sometimes we are too clever for ourselves, and sometimes "improvements" (eg. in lubrication) can cause other things to fail, which leads on to.....

Figure 9: Close up - Rider Roll end. Figure 10: Penrose Mill Winder

Figure 11: Rider Roll Bearing Failure




Figure 11: Rider Roll Bearing Failure

Figure 9: Penrose Mill Winder

Figure 10: Close up - Rider Roll end.

continued

still the same failure mechanism - cage failure then the rollers turning. Finally we decided to go back to the original “basic” grease. The failures appear to have stopped. By then we had also capexed a new Rider Roll (About EUR 40k) and have recently installed it.

What did we learn? Sometimes we are too clever for ourselves, and sometimes “improvements” (eg. in lubrication) can cause other things to fail, which leads on to.....

Electric Motor greasing.

The correct procedure for greasing electric motors seems to generate a bit of interest on reliability pages. One of our experiences was “interesting”. Our motor repairer had noticed that some of the bearings coming out of our electric motors were quite “dry”, so he suggested that the motors be greased more frequently.

This was mentioned to our Lube technician who leapt into action and doubled the greasing frequency. About a month later we started having some motor failures. (See below)




Figure 11: Rider Roll Bearing Failure Figure 11: Rider Roll Bearing FailureElectric Motor greasing. The correct procedure for greasing electric motors seems to generate a bit of interest on reliability pages. One of our experiences was “interesting”. Our motor repairer had noticed that some of the bearings coming out of our electric motors were quite "dry", so he suggested that the motors be greased more frequently. This was mentioned to our Lube technician who leapt into action and doubled the greasing frequency. About a month later we started having some motor failures. (See below)

Figures 12: Electric Motor Over-greasing failure After the second one in two months the question was asked - what has changed? And the answer came out along the lines of "Oh, someone said the bearings were dry so they needed more grease - so we gave them more grease...“ Who approved the change? No-one. The original grease schedule was immediately put in place again and the problems disappeared. We weren't having a problem in the first place! Disperger The Disperger is machine used to evenly distribute the ink through the paper pulp, so that no large ink splotches can be seen in the finished product. VA is done regularly on this machine, however early warning is also from when one of our foremen is sitting on the toilet in Stock Prep and can feel the floor vibrating. The motor is 500kW and the machine runs at 4 pole speed. The machine operates in hot conditions (steam and water are

Figures 12: Electric Motor Over-greasing failure

continued

After the second one in two months the question was asked - what has changed? And the answer came out along the lines of “Oh, someone said the bearings were dry so they needed more grease - so we gave them more grease...“ Who approved the change? No-one. The original grease schedule was immediately put in place again and the problems disappeared. We weren’t having a problem in the first place!

Disperger

The Disperger is machine used to evenly distribute the ink through the paper pulp, so that no large ink splotches can be seen in the finished product. VA is done regularly on this machine, however early warning is also from when one of our foremen is sitting on the toilet in Stock Prep and can feel the floor vibrating. The motor is 500kW and the machine runs at 4 pole speed. The machine operates in hot conditions (steam and water are introduced into the stock inside the machine and it has an “awkward” bearing arrangement. (See Figure below)

There have been a number of failures of the triple angular contact bearing arrangement at the NDE. Always the “lightly loaded” bearing is the worst. Some photos of one of the worst failures are shown below. The inner race of the centre bearing has deformed over the adjacent bearing due to the extreme conditions immediately before failure.

See Figure 14 on next page

A brief history…

2006: Bearings failed. Changed to a different grease and changed the greasing regime with the bearing supplier. We were guessing that clean grease wasn’t getting right through the angular contact pack.

2007: Went to a high temp grease to help the greasing.

2008: Bearings failed again. Decided to change (simplify) the bearing order to try and help the greasing and load path.

introduced into the stock inside the machine and it has an “awkward” bearing arrangement. (See Figure below)

Figure 13: Disperger Sectional View There have been a number of failures of the triple angular contact bearing arrangement at the NDE. Always the “lightly loaded” bearing is the worst. Some photos of one of the worst failures are shown below. The inner race of the centre bearing has deformed over the adjacent bearing due to the extreme conditions immediately before failure.

Figure 14: Disperger Bearing Failure A brief history… 2006: Bearings failed. Changed to a different grease and changed the greasing regime with the bearing supplier. We were guessing that clean grease wasn’t getting right through the angular contact pack. 2007: Went to a high temp grease to help the greasing. 2008: Bearings failed again. Decided to change (simplify) the bearing order to try and help the greasing and load path. 2009: Bearing Failure. Went back to the original OEM specified basic grease. 2009: The latest iteration is to reduce the size (series) of the angular contact bearings to more closely replicate the load rating of the original bearings in the machine. Time will tell….

Figure 13: Disperger Sectional Viewcontinued

introduced into the stock inside the machine and it has an “awkward” bearing arrangement. (See Figure below)

Figure 13: Disperger Sectional View There have been a number of failures of the triple angular contact bearing arrangement at the NDE. Always the “lightly loaded” bearing is the worst. Some photos of one of the worst failures are shown below. The inner race of the centre bearing has deformed over the adjacent bearing due to the extreme conditions immediately before failure.

Figure 14: Disperger Bearing Failure A brief history… 2006: Bearings failed. Changed to a different grease and changed the greasing regime with the bearing supplier. We were guessing that clean grease wasn’t getting right through the angular contact pack. 2007: Went to a high temp grease to help the greasing. 2008: Bearings failed again. Decided to change (simplify) the bearing order to try and help the greasing and load path. 2009: Bearing Failure. Went back to the original OEM specified basic grease. 2009: The latest iteration is to reduce the size (series) of the angular contact bearings to more closely replicate the load rating of the original bearings in the machine. Time will tell….

2009: Bearing Failure. Went back to the original OEM specified basic grease.

2009: The latest iteration is to reduce the size (series) of the angular contact bearings to more closely replicate the load rating of the original bearings in the machine.

Time will tell….

EDM

Our DC Motors have started getting EDM failures since we changed from tacho-generators to encoders (loss of a minor earthing loop). We have installed DC motor earthing brushes (the same earthing brush as are installed in an Inproseal shown by Tom Pape at the VANZ conference in Hamilton). Since then we have had less failures, although we have just changed a motor we installed the brush on too late - the damage had already started.

Where to now?

We still have many things we are working on at Penrose Mill.

In no particular order some these are:

• Documenting our “institutional knowledge”. We need to capture the information from our experienced staff for several reasons. Given Auckland traffic on a rainy day, they might have the misfortune to be involved in an accident and it also means that the foremen or leading hands do not have to give continuous instructions on how to complete a task.

• More accurate work order instructions (Precision maintenance). Unfortunately with the demise of the apprenticeship schemes for a number of years there does not appear to be anything like the skills and pride in workmanship that we need to get better. Also a lot of the good guys are retiring.

• On the run inspections eg. for couplings & v-belts as per Christer Idhammar

• Reducing stock/working capital

• Basic care by operators differs depending on the shift crews - some are good. We haven’t done training or development on this yet.

Figure 14: Disperger Bearing Failure

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1 Vibration test disks are fitted to measurement points on the machines at a manufacturing facility. The advantages of these disks are …

a The tests points are still identifiable even after the machine has been cleaned or painted

b The flat surface of the disk provides enhanced and more consistent transmission of high-frequency signals in compari-son to the housing surfaces which may be curved, rough, or uneven.

c The unreliable transmission of high-frequency signals arising from loose or overly thick paint layers is eliminated.

d All of the above.

2 A multi-stage pump is coupled to (and driven by) a 3-phase induction motor not operating on VSD Control. The pump’s vibration levels were well above normal levels when a routine test was undertaken. The pump was re-tested two weeks later and the vibration levels were back to normal. It is suspected that flow conditions and loading might have been well outside the normal range during the “bad” test. Suction and discharge pressures were not logged during the monitoring, nor was the motor current. However the routinely collected data might still give some indication of the loading conditions for each test. Which of the following is true?

a Examine the high-frequency signals – they will always be higher when the loading is high

b Axial vibration levels will always be higher on coupled units when the loading is high

c Providing there is sufficient frequency resolution, the main forcing frequencies (often 1x) of the spectral data could be reviewed – usually the frequency of such peaks will reduce as the load is increased (and vice-versa)

d Both b and c are correct

3 A VA analyst made an unusual, but highly effective, recommendation to apply grease to a machine to reduce its 1 x vibration which routine tests showed had been slowly increasing over a number of months. This was done as a quick-fix measure prior to the machine having more extensive work done on it at a later date. Which of those below is likely to be the machine/ greased-component in question?

a Belt-driven fan – fan bearings greased

b Belt-driven fan – motor bearings greased

c A direct-coupled hydraulic pump on a press – the 1x vibration was (prior to greasing) only strong during the loaded cycle – coupling greased

d A direct-coupled hydraulic pump on a press – the 1x vibration was (prior to greasing) strong during both the loaded and unloaded cycle – coupling greased

4 In order to be sure of his analysis, a VA consultant requested from the service providers some bearing information for a machine. The emailed response was surprising: “up here in xxxx we have varying levels of VA people considering themselves experts and causing difficulties when they are not by any means experts…..I have had to deal with a lot of bad calls by VA “experts””. Compared to 25 years ago, there are large numbers of people attending VA training courses, and there are now certification methods. Despite this, which year do you think this communication took place?

a 1988

b 2008

c 2012

d 2015

5 BNC connectors are still widely used in the process of collecting vibration data – particularly when connecting to permanently-wired transducers. Which of the following is true about these connectors?

a They are excellent all-weather connectors which can be left exposed to the elements

b The large size of these connectors makes them difficult to use in many applications

c Corrupt data can result if the connectors are not kept clean and dry

d Both b and c

TEST YOUR KNOWLEDGE - PART 40 OF A SERIES

6 A fan with a large overhung impeller was showing strong 1x vibration which could only be partially reduced with single-plane insitu balancing techniques. There was not sufficient access to allow 2-plane balancing to be attempted in-situ, so it was recommended that the fan was 2-plane “shop” balanced during the next scheduled plant outage. This was done and vibration levels were reduced to an acceptable level. Which of the following might show on the 2-plane balancing report regarding phase separation of the correction weights?

a The report might show 180 degrees

b The report might show 210 degrees

c The report might show 0 degrees

d Either a or b is likely, but c is very unlikely

7 Although rare, it is possible for an electric motor to suffer from resonance in the mounting feet when it is correctly bolted down without soft-foot. Which of the following might be correct with regard to an analysis of this condition?

a Loosen the hold-down bolt on one or more of the feet; the vibration levels might well reduce

b Run the motor uncoupled; the vibration levels will always reduce

c Evidence of this condition will be seen by the presence of harmonics in the collected spectra

d Rule this out as a possible cause as the vibration on this motor is sourced at 2 x line frequency

8 Vibration analysers are sometimes powered by Lithium-ion batteries. Which of the following is true of this type of battery?

a The life-span of this battery is limited to 700 charge/discharge cycles

b The battery is known to develop seriously-reduced capacity with time due to memory-retention

c Lithium-ion batteries have been known to catch fire which is why they are not viewed favourably by the airline industry

d None of the above

9 The detection of rolling-element bearing faults on slow-speed equipment can be challenging. Which of the following is true of the enhanced signal-conditioning techniques included in many vibration analysers used for this type of monitoring?

a In some instances the time waveform might yield more valuable information than the spectra

b Waveform should never be used when analysing slow-speed rolling-element bearings

c It is crucial that phase data is collected to assist in the detection of these faults

d When using these enhanced signal conditioning techniques, the data should always be viewed in displacement

10 What advantage might a 500mV/g accelerometer have over a 100 mV/g accelerometer?a Increased signal to noise ratio for low-level vibration measurement

b The 500 mV/g accelerometer will most likely be smaller

c The signals might be more audible when listening via an audio-output device attached to your analyser

d Both a and c could be correct

ANSWERS on page 36

Further enquiries can be directed to: Carl Townsend at Carlton Technology Ltd

ph 64-6-759 1134

P O Box 18046 Merrilands,New Plymouth 4360, NZ

email: [email protected]

QUIZ

ANSWERS

SPECTRUM 62 page 30

The Magazine will include:

Cover – Full colour adverts inside front cover, inside back cover and back cover

Content – 16 to 24 pages black and white with centre colour pages

• Adverts full, half and quarter page • Papers from conference reprinted

• Conference info • Presidents Report • Notices – Committee report

Advertising Rates (all rates plus GST the inclusion of their adverts onto the VANZ website).

Inside front or back cover full colour Payment for EACH issue $400 per issue

Outside back cover full colour Payment for EACH issue $450 per issue

Inside magazine black & white (Payment for EACH issue)

full page $300 / issue half page $250 / issue quarter page $200 / issue

Inside magazine centre page – full colour (Payment for EACH issue)

full page $350 / issue half page $300 / issue quarter page $250 / issue

Advertorials - $100 b&w full page (b&w graphic optional) or 50% discount if bought in

conjunction with a full page colour ad

Insert mailed out with magazine $350 per issue. Please contact Angie Hurricks for more details.

All advertising copy to be supplied as CMYK high resolution PDF format ready for print.

The NEXT SPECTRUM will be distributed shortly so be in QUICK with your adverts.

Email Angie at [email protected] to confirm your advert position and method of

payment as soon as possible. Articles are also welcome, copy to be either in MS Word or PDF

file format, with pictures and graphics in jpeg format and sent separately.

Come aboard and help VANZ through

www.vanz.org.nz

QUIZ ANSWERS from page 26

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a d d d c c b d c b1 2 3 4 5 6 7 8 9 10

D C C D C D A C A D

www.eurotec.co.nz ph: 09 579 [email protected]

Testo thermal imaging cameras can be used in the following sectors:• Food Processing • Mechanical • Structural • Electrical Maintenance• HVAC Engineering • Research and Development

Thermal imaging cameras are fast becoming an important tool for a multitude of applications, helping you identify weak spots and damage effectively.

We measure it.

Top level thermography.Don’t waste time looking for hotspots. Find them!

An Innovative API670 Compliance Rack Based Asset Condition Monitoring and Machinery Protection System

SETPOINT™ – Machinery Protection System (MPS) Key Features: Full API 670 compliance Industry first integral Colour Backlit Touchscreen display Totally open data access 19” rack or Bulk Head mounting to save space Up to 60 channels in just 19” of rack space. Multiple, Segregated Processors Can be retrofitted to replace your existing system

Applications: Turbines and Rotating machinery Reciprocating & radial compressors Pumps/Fans/Cooling systems

Condition Monitoring Software (CMS)

Online, continuous collection of vibration and condition data from connected SETPOINT Machinery Protection System (MPS) racks, allowing trending, diagnostics and predictive maintenance of monitored machinery for Up to 300 Channels and with Native interface to OSI Pi.

Digital Proximity Probe System (DPS)

Fully programmable - Fully Digital - Fully API 670 compliant – Fully Awesome.

Single programmable Proximity probe which can be configured to work with any probe/cable/target-material combination.

Supports probes from a variety of manufacturers. Field Calibration One driver for all applications

For more information: Call our sales team on: (09) 271 3810 Email: [email protected] Visit: www.cse-waf.co.nz

Spectrum 76 May 2015

Documents

Transcript of Spectrum 76 May 2015