protective maintenance fans cement
Post on 25-Jan-2015
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INSTRUMENT CO.INSTRUMENT CO.METRIXMETRIXPMC/BETAPMC/BETA
Strategies for Vibration Monitoring
The 4 “PM’s” Preventive Maintenance Predictive Maintenance Proactive Maintenance Protective Maintenance TM
Why Protective Maintenance?
Basic vibration
Fan applications
How much protection is enough?
Visit www.cbpowerandindustrial.com
INSTRUMENT CO.INSTRUMENT CO.METRIXMETRIXPMC/BETAPMC/BETA
Current Condition Monitoring Practices
Periodic monitoring using portable data-loggers Periodic monitoring using portable data-loggers Usually “owned” by maintenance/contractor Strong analytical tool: The masters of the “squiggly lines”
“Spend 85% of their time on healthy machines” Heinz Bloch, Consultant
Full time protection from installed instrumentationFull time protection from installed instrumentation If installed at all, usually “owned” by operations Very little knowledge of vibration expected or required of operators Total installed cost is a factor in decision to protect or not
INSTRUMENT CO.INSTRUMENT CO.METRIXMETRIXPMC/BETAPMC/BETA
Protective Maintenance TM
Tearing down the (cement) walls between operations & maintenance Combining the assets available for effective condition monitoring
Full time protection from installed instrumentation Consider lower cost alternatives now on the market Local indication (on protection device) & remote overall vibration trending
Pocket sized overall vibration meters for Operator to use on frequent rounds Easy, safe data access for Analyst to diagnose faults and take corrective action
INSTRUMENT CO.INSTRUMENT CO.METRIXMETRIXPMC/BETAPMC/BETA
Benefits of adopting a program of Protective Maintenance TM
Get 24-7 real-time protection of important plant assets Get operators more involved in the process of protecting their machines
Help operators quantify an important operating parameter
Call in vibration analyst (contractor) when needed Complements existing condition monitoring programs Analysts spend time more effectively on sick machines, not healthy ones.
Aids the analyst to get easy, safe access to dynamic data Develops more consistency in the technique of data acquisition Trends become even more valuable
Pays for itself and puts money to the bottom line What is the value of one or two “saves” in a year?
INSTRUMENT CO.INSTRUMENT CO.METRIXMETRIXPMC/BETAPMC/BETA
Basic Vibration: simple yet complexor all an Operator needs to know about vibration
Sound: vibrating vocal chordsSound: vibrating vocal chords
Overall sound level: LOUD or soft
Very complex: Bing or Sting; Bocelli or MinelliOrca’s sound pattern
Light: from the sunLight: from the sun
Overall: Bright or dim
Very complex: Prism
Vibration: from rotating equipment:Vibration: from rotating equipment:
Overall vibration: High or low
Very complex: Spectrum analyzers
INSTRUMENT CO.INSTRUMENT CO.METRIXMETRIXPMC/BETAPMC/BETA
Fan protection & condition monitoring in a “dry process” plant
Dry process plant synopsis
rotary kiln
raw millelectro-st
precip
coal mill
sep
sep
sep
electro-st precip
cement mill
sep
cooler
Stack
Stack
raw millexhaust
coal injectioncoal mill exhaust
preheater exhaust
cooler exhaust
electroprecipitator exhaust
cement millexhaust
cooler FD fan
cooler recirculation
INSTRUMENT CO.INSTRUMENT CO.METRIXMETRIXPMC/BETAPMC/BETA
What are the most common Root Causes of Fan vibration?
mounting mounting & &
foundation problemsfoundation problems
motor anomaliesmotor anomalies
bearing wearbearing wear
Journal/sleeve
“anti-friction”
misalignmisalignment
ment
& other frequencies of interest& other frequencies of interest
Significant overall vibration change Significant frequency change
INSTRUMENT CO.INSTRUMENT CO.METRIXMETRIXPMC/BETAPMC/BETA
Location on Fan for Monitoring Vibration Ideally, on each bearing of a machine
Analysts typically take 9 readings per direct coupled machine For analysis, 1- vertical & 1-horizontal per bearing & 1-axial per machine
“If I take just one measurement, where is the best place on the machine?” 1-horizontal on the inboard bearing cap of the driven equipment This is also the best place to mount a single protection device
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INSTRUMENT CO.INSTRUMENT CO.METRIXMETRIXPMC/BETAPMC/BETA
Vibration Instrumentation for Protective Maintenance TM
Permanently installed protection monitors Local or remote shutdown or alarm only With local indication for operators With 4-20 mA to DCS for trending With easy access to dynamic data for the vibration analyst
Operators use a vibration meter on rounds Machines “owned” by operations Operators quantify overall vibration frequently; continuously Machines seen frequently bringing 5 senses to bear
Analysts (maintenance) do periodic data collection & detailed analysis Highly trained specialists with expensive tools More time to spend on “sick” machines More time for proactive work
INSTRUMENT CO.INSTRUMENT CO.METRIXMETRIXPMC/BETAPMC/BETA
“How much protection is enough for your operation?”
First, Decide on a strategy that suits your operationFirst, Decide on a strategy that suits your operation Assume “Protective Maintenance” suits your needsAssume “Protective Maintenance” suits your needs
Start “teaming” operations & maintenance up front Classify your machines
Critical - Important - Balance Of Plant (BOP) Plan to install vibration monitoring instrumentation on all critical machines
Dedicated monitor, multi-machine monitors, transmitters to your PLC/DCS Consider installing monitors or switches on important machines Outfit operators with “pocket” vibration meters for use on rounds Analysts to establish a simple technique & set expectations with the operators
Where & how to measure vibration on each machine: mark the machines Optional operator logging procedure
Use a capital project to get all or part of the solutionUse a capital project to get all or part of the solution Use incremental methods for all or part & eUse incremental methods for all or part & ease into budget & sign-off issues
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