Due to positive feedback from our previous 5 case studies series this is our bonus case study brought to you with the Reliability Training Institute. If you have missed any of the previous case studies, they can be found on my LinkedIn profile, Seasoned Analyst blog and on the RMS Website.
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This case study is a lot longer at over 34 minutes. Here we cover a 2-year project period from initial root cause diagnosis to designing, trialling, and implementing an innovative cost-effective solution.
This was to be the final of the five case studies brought to you with the Reliability Training Institute. But, following on from feedback we will have one more case study next week, this will be an extra long project case study!
In this case study we demonstrate vibration analysis of a slow rotational 4 Point Contact Bearing, with a 23RPM Defect. This is to remind us that correct database set up, and Time Waveform Analysis is so important in slow rotational bearings.
In this case study we show that by measuring the correct vibration parameters you can resolve defects in harsh applications, even an inner raceway defect on a vibrating screen. Hopefully, you are finding them of use and helpful.
Here is the third of the five case studies brought to you with the Reliability Training Institute. In this case study we show how vibration analysis detected a hidden failure in a variable frequency drive. Hopefully, you are finding them of use and helpful.
As promised and to follow up on my previous post on bearing failures here is the first of five technical detailed case studies presentation. This is my first voice over presentation so please excuse the English Farmer accent mixed in with some Australian twang.
Hello everyone, I have created short presentation to share some different bearing failures that were detected before function failure. This has been put together for meetings and toolbox talks to promote the benefits of what defects a condition monitoring program can detect. Every bearing here has a story of how it was detected and what actions were/were not put in place to protect the functionability of the system.
This is aimed to highlight (at a high level) to management and production what we can detect if a suitable system is set up correctly.
I am working on another case study presentation that follows up on these and some other cases. In this one it will have the technical testing data (thermal, electrical and vibration) and a full case study also showing the ‘The Cause’ ‘The Mechanism of Failure’ and ‘The Failure Mode’. This will be posted over 5 videos.
Please feel free to share and spread the knowledge
Increase your Plant Reliability
and Increase Profit with a Seasoned Analyst.
Do you have unplanned failures? –
How much is this costing the company per hour? – Do you have any repeat
failures that causes disruption to production? – Are you firefighting faults? –
Do you have any equipment that is vibrating heavily that you can’t reduce? –
How can you improve your current maintenance practices?
Many companies don’t have the
expertise of a Seasoned Analyst to help them increase Plant
Reliability via an effective Condition Monitoring Program. Attached is a PDF
that contains information that can assist you in this.
With over 30 years’ experience in
the fields of Vibration Analysis, Infrared Thermography, Condition Monitoring
and Maintenance Engineering I have put together a book that your Engineers and
Maintenance Team will find extremely useful. Having worked with many of the
Blue-Chip companies in the UK and Australia, I have collated my experiences to
help and support the Non-Seasoned Analyst.
My experience ranges from
Lubrication, Thermal Imaging, Vibration Analysis, Ultrasound, NDT, Maintenance
Planning, Maintenance Improvements, Project Management and Mechanical
Maintenance including on site Dynamic Balancing and Laser Alignment.
I can provide an integrated condition
monitoring support service that will manage and drive your maintenance tasks
through Health Based Maintenance. This will enable you to know the health of
your system, engineer out repeat defects and increase production uptime.
Please read the attached book flyer for more details of how we can help you and your team. If you require further information, please contact us
A profitable plant is reliable, safe and a cost-effectively maintained plant.
The Seasoned Analyst
CBM Conference 2019 UK
I presented at my first Conference, and it was the first CBM Conference in the UK. It was well worth attending as I got to discuss various challenges in the condition monitoring and reliability sector, and the most common discussion point was buying from senior management and how to continually highlight the benefits of a condition monitoring program.
In addition there were vendors there demonstrating the latest advancements in condition motioning technology from vibration online and walk around, thermal imaging safety, ultrasound new high sampling rates time waveform analysis to motor electrical condition monitoring.
When all else fails, leave the air conditioning, and go examine the operating equipment. Go look, touch, feel, smell and listen to the machinery.
The seasoned Analyst
Online vibration monitoring is a great tool that enables monitoring of a vast number of assets, it helps the analyst when they “can’t see the woods for trees”.
This post is to highlight that for a full assessment of an asset you don’t just sit in your air conditioned office looking at the data on the screen. You must use other technologies and inspection tools to assess the Reliability of the system, the best tool is experienceand your human senses.
The SPM online system alarmed on a fan bearing. This fan has a direct drive AC motor to a fan lay shaft with two SKF/Cooper split bearings.
The onsite vibration analyst called for an inspection of the bearing due to mechanical/component looseness and an outer race defect. I was asked to confirm the diagnosis and provide further details.
On review of the data, and the new on demand live data, from the SPM system I concluded that the analyst was correct in the diagnosis of mechanical/component looseness and an outer race defect on the split bearing.
Figure 1 is
the SPM online Velocity spectrum from the 1st September, with low
overall one order and no harmonics.
Figure 2 is the SPM online Velocity spectrum on the 3rd September, and shows many running speed harmonics indicating a component/mechanical looseness.
Before I issued my comments I decided to “Leave the air conditioning, and go examine the operating equipment. Go look, touch, feel, smell and listen to the machinery”. Within seconds I spotted the issues and using my personal Motion Amplification tool, my finger! I felt and confirmed what my eyes were seeing.
Image 1 is of the drive end (Motor side) split bearing, all good.
Image 2 is of the fan NDE bearing (Fan side). The top cap retaining bolts were coming loose!
This was reported immediately to the on site maintenance team. Maintenance re-secured and torqued the bearing top cap bolts. It was found that both bolts were loose!
Post Vibration Analysis:
Figure 3 is the SPM online Velocity spectrum after the corrective actions, 3rd September. This shows a large reduction in the 1 order harmonics, confirming the loose bolts were the cause of the harmonics. It was also noticed that there were still some higher frequency data evident that was not there prior to the 3rd September.
analysis of the SPM HD Envelope spectrum displayed a clear defect signal for
the outer raceway. This is a split bearing so you would expect to see some
bearing signal but the fan end is a lot higher. This is not surprising giving
that the fan end bearing was in operation with a loose top bearing cap!
The data below compares the drive end (motor side) Figure 4 and non-drive end (fan side) Figure 5 SPM HD Envelope spectrum. This confirming that the fan end bearing signal is a lot higher.
This highlights that there is a place for an online monitoring system in some aplications.
In addition to preventing a catastrophic failure of the fan and this having a effect to the profitability of the site, this prevented what could have been a very dangerous safety incident with a fan coming loose at full speed.
For a full assessment of the system please leave
the air conditioning, and go examine the operating equipment. Go look, touch,
feel, smell and listen to the machinery. Don’t site and rely on one form of
data to make a decision that will affect the reliability and probability of the
A profitable plant is reliable, safe and a cost-effectively maintained plant.