 Portable
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Predictive Mechanical Maintenance Through Vibration Measurement
RESOURCES - Balance Tolerance Calculator
Corvib has been involved with vibration analysis for over 20 years. We have always maintained that with the equipment, training and/or outsourced help that is available, there is no reason or excuse to have machinery operate unprotected.
The areas of interest in vibration measuring in plant maintenance are general measurement, analysis, and corrective. We will address them individually
The purpose of vibration monitoring is to establish the running condition of machinery in a fashion which is objective and scientific. While experienced opinions as to how a machine is operating is helpful, these opinions do not take the place of scientific "metering" to obtain the true condition of rotating machinery. Also, there is no better criteria for operational soundness in rotating machinery than by how much it vibrates. While the CSNDT Journal recently dedicated an issue to Thirty Years of Condition Monitoring in Canada, it is generally accepted that we under utilize this technology in Canada and The United States as compared to our European counterparts. The competitive disadvantage to our industries and institutions cannot be understated. Companies that use Vibration monitoring have many advantages -
Less Downtime
Less Spare Parts Inventory
Better Management Time Allocation
Less Overhaul-Overkill
Longer Production Runs
Better Quality
Although the recording of vibration data can be performed with equipment as basic as a meter and a pencil and paper, advances in technology enable computer assisted data collection which provides much more detail in a fraction of the time . There are many vendors who can sell instrumentation, or you may choose to out-source.
With the benefits of a predictive program as great as they are, the uninitiated could look at this technology as a great new source of profit potential. Greater profit is realized with a minimum of capital expenditure, no layoffs and greater acquired skills.
Using a vibration analyzer, and some skill, personnel can pinpoint the causes of rough machinery condition. Such problems as rotor imbalance and misalignment make up a great proportion of mechanical deficiencies and can be identified and rectified. Other problems such as bearing wear are not only detected, but also qualified as to the severity of wear. In many instances, a historical case study can prognose the remaining life of bearings so that scheduled repairs can be prioritized.
Techniques for analyzing machinery are well documented and are taught by instrument suppliers and formal education facilities.
By far, the most predominant utilization of vibration corrective measures are that of balancing. More than a trial and error method of achieving dynamic trueness, balancing with an analyzer is a stepped process. It is one of very few techniques where machinery which is deemed "rough" can be corrected in place, without disassembly and where the results can meet any level of precision in almost all cases. This is especially helpful when one considers that the same analyzer pinpoints imbalance conditions so that the cause and cure are achieved with the same instrument.
Vibration analyzers can be used for running alignment. We have seen cases where an analyzer is used throughout the alignment procedure to detect the source of high vibration or to detect the effects of fastening. Also, soft-foot conditions can be detected and corrected while the machine is operational. This creates a fast diagnosis-correction situation without having to stop and start the machinery.
There are many other instances of vibration monitoring, analysis, balancing and corrective measures that make this technology so effective.
"We don't have a vibration problem"
"vibration" is not a problem - it is a physical manifestation of machinery imperfection. It is used to help find obvious and subtle deviations in machines. No machine runs perfect.
"balance that machine"
This is a request that is made before a condition of imbalance is established. It is not just a matter of semantics either. If in fact, the machine is imbalanced, corrective action can be taken and the machine can operate within tolerances. If it is not imbalanced, the vibration analyst will advise the corrective action but cannot use the analyzer to fix the problem directly. It is a matter of expectations and in some cases, disillusionment.
"that machine is fine - we've just changed the bearings"
This is stated as a reason for not analyzing a machine. Bearings do fail as a matter of fact. After a certain amount of time, maybe a month, maybe a decade, bearings will finally succumb to slight or severe wear criteria and will fail. Assuming however, that bearing replacement is the final solution is a folly.
The bearing replacement trap occurs when the old bearings are noisy or fail. The millwrights are charged with replacing them and the new ones are now quiet - problem solved -
Wrong!
Bearing failure could be an indication of the natural expected life of the bearing itself but it should send alarm bells that this is a primary candidate for analysis. The failure could be the manifestation of the mechanical deviations in a machine that could be corrected if one were to know about them. Also, the best time to get a vibration profile for future comparisons are when the machine has been reconditioned. This helps to find any inherent fault in the machine as well as determine if the work performed on it was done to specification. Also, remember the best programs are the ones that have the most historical information.
"that machine always runs like that"
And it always will until you fix it! Vibration analysis can tell you how.
"when it fails, we repair it"
The fact is, the machine will fail at its discretion (if it had any) and not to your schedule. When it fails, it will cause secondary damage. The parts for many machines must be kept on hand ahead of time to minimize the time it takes to repair. Plant production will cease. Personnel will be reallocated.
On The Other Hand
A more constructive approach leads to efficient, cost effective action -
"we replace worn parts before they fail"
Using vibration analysis, you have a list of "invisible" anomalies. This list will show problems long before failure which will allow repairs to be scheduled during off hours. Problems with bearings are detected long before they fail so that other associated mechanical components are unaffected. Parts are not seized, no shafts are broken so the repairs are done in a fraction of the time. During repairs, other machines that have impending problems detected with vibration monitoring can be corrected. The parts have been ordered as needed.
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