One of the most powerful tools to deploy reliability centered maintenance are portable vibration measurements. With the new portable vibration analyser of Emerson, portable vibration analysis is now made easier than ever before. By the following slidedeck you'll get an introduction to the basics of vibration analysis and the capabilities of the CSI2140
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Vibration Analysis, Emerson Makes it Easy for You
1. Introduction to PortableIntroduction to Portable
Vibration AnalysisVibration Analysis
Dieter Charle
BDM Portable Reliability Solutions | Europe
5/11/2015
2. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 2
US $24.5 Billion in Sales
Emerson At-A-Glance 2015
Manufacturing
and/or sales presence
in more than
150 countries
220 manufacturing
locations
around the world
No. 121 on 2014
FORTUNE 500 list of
America’s largest
corporations
Founded in 1890
NYSE: EMR
Headquarters in
St. Louis, Missouri USA
Diversified global manufacturer
and technology provider
Approximately
115,000 employees
worldwide
3. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 3
Emerson Invests in New Technology Development
to Meet Customer Needs
$805 million … Emerson’s investment in
Engineering & Development during 2015
1,900+ … patents awarded in 2015
to Emerson businesses
4. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 4
US & Canada
Sales $11.2 Billion
Employees 32,000
Locations 75
Latin America
Sales $1.5 Billion
Employees 18,000
Locations 30
Western Europe
Sales $3.8 Billion
Employees 16,000
Locations 45
Middle East & Africa
Sales $1.5 Billion
Employees 1,000
Locations 5
Eastern Europe & Russia
Sales $1.0 Billion
Employees 9,000
Locations 15
Asia
Sales $5.5 Billion
Employees 39,000
Locations 50
Note: Locations include manufacturing locations only.
Our Business Objective
To design, engineer, manufacture, sell and support
our products and solutions in every region of the world
Emerson Global Presence 2015
5. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 5
Our Industry Challenges
• Eliminate unplanned production shutdowns
– Minimize exposure – safer work environment
– Improved uptime
• Prioritize and plan maintenance actions
• Extend time between planned shutdowns
• Reduce inventory costs
• Increase availability and performance of assets
• Reduce preventive maintenance
MotorsMotors PumpsPumps TurbinesTurbinesGearboxesGearboxes
7. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 7
Portable Vibration Analysis – Industry Requirements
• Easy Routine Data Collection
• Get Faster Diagnoses
- Coherence case history
- Complex, hard to access machinery
• Advanced Diagnostics
- Detect misalignment during operation
- Live monitoring sleeve bearings
- Commissioning smaller turbines
- Structural Analysis
StandardAdvanced
8. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 8
Vibration Analysis
"Of all the parameters that can be measured non-intrusively in
industry today, the one containing the most information is the
vibration signature.“
- Art Crawford, Consultant / Author -
In one study, nearly two thirds of the
entire benefit from Machinery Health
Monitoring came from Vibration Analysis
- John E. Amos Power Station -
65% Vibration
Analysis
9. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 9
Vibration Analysis – Basic Principle
• Mechanical faults generate unique vibration
– Geometry of the machine
• diameter of the shaft
• number of bearing elements
• Type of bearing elements
– Turning speed (e.g. RPM)
HighLow
Mechanical Defects detected with
vibration analysis
Belt drive faults
Imbalance
Misalignment
Bent shaft
Shaft Rub
Looseness
Machine resonance
Bearing Defects including:
•cage defect
•outer race defect
•inner race defect
•rolling element defect
Gear defects
Electrical faults
Cavitation
Lubrication
10. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 10
Vibration from Mechanical Faults
11. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 11
Vibration from Mechanical Faults
Imbalance
1 x RPM
12. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 12
Vibration from Mechanical Faults
Blade Pass
4 x RPM
13. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 13
Vibration from Mechanical Faults
Gear Mesh
17 x RPM
14. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 14
Vibration from Mechanical Faults
Blade Pass
4 x RPM
Gear Mesh
17 x RPM
+
Imbalance
1 x RPM
+
15. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 15
Frequency
Amplitude
How the Vibration Spectrum is Created
Time
Amplitude
Time
Amplitude
16. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 16
Roller Bearing Faults
Four different bearing frequencies
Ball Pass Frequency
Inner Race
(BPFI)
Ball Pass Frequency
Outer Race
(BPFO)
Ball Spin Frequency
(BSF)
Fundamental Train
Frequency
(FTF)
17. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 17
How Bearing Faults Generate Vibration
18. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 18
One tool to WIN all challenges
Industry Requirements Modular Multi-Technology Platform
Easy Routine Data Collection • Vibration Routes
• PeakVue Analysis
Get Data Faster
- Coherence case history
- Complex, hard to access machinery
• 4-channel Analysis
• In-field Alarming
• Fault Frequencies
• Parameter Trending
Advanced Diagnostics
- Detect misalignment during operation
- Live monitoring sleeve bearings
- Commissioning smaller turbines
- Structural Analysis
• Cross Channel Analysis
• Vibration Analysis/Troubleshooting
• AC Motor Rotor Bar Analysis
• 4-Plane Balancing
• Dual Orbit Plotting
• Transient Analysis
• ODS/Modal Analysis
StandardAdvanced
19. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 19
Lower Cost = Earlier Warning = PeakVue
PeakVue is easy!
• One single value to interpret
• Earlier warning than any other
technology
• Indication of fault and severity
Progression of a Typical
Machine Problem
PeakVue
Alert
EquipmentHealth
Time
EquipmentEquipment
FailureFailure
PeakVue
alert Oil
analysis
Temperature
monitoring
Overall
Vibration
Audible
noise
Hot to
touch
Spectrum
Analysis
Vibration
analysis
Consequence
Time
Easy
20. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 20
Vibration
in/s mm/s
Minimal Warning
0.15 / 3.7 Good
0.15 / 3.7 Good
0.15 / 3.8 Good
0.16 / 4.0 Good?
0.18 / 4.5 OK?
0.30 / 7.5 Failure occurs!!!
Onsetof
Fault
Bearing
Failure
FAULTFAULT
ALERTALERT
FAULTFAULT
ALERTALERT
No
Warning!
Time
To
Plan
PeakVue
g’s
Early Warning with Severity
0 Good
10 Alert – Notify maintenance
20 Problem getting serious.
30 Near end of life
40 Take action! Bearing failure imminent
50 Failure occurs!!! 0
10
20
30
50
40
0.0
0.1
0.2
0.3
0.4
0.5
PeakVue(g’s)Vibration
0.0
2.5
5.0
7.5
12.5
9.0
After
Repair
Overall Vibration vs. PeakVue Easy
21. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 21
PeakVue is Easy
Two Simple Rules:
PeakVue
(g’s)
Interpretation
0 Good machine
10 Some Issue
20 Serious problem
40 Action Point
Reliability 101 for Operators
2. Rule of 10’s
• 10 – something’s happening
• 20 – something serious happening
• 40 – time to take action
1. Zero Principle
PeakVue on a good machine
is at or close to zero
Easy
22. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 22
The magic behind Vibration Analysis
Enveloping registers (Demodulation)
Raw measurement data - Waveform
Signal after rectifying
Signal after band pass filter
Easy
23. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 23
The magic behind Vibration AnalysisPeakVuePeakVue
Peak Impact Detection registers
Raw measurement data - Waveform
Signal after rectifying
Signal after band pass filter
Easy
PeakVue:
-Keep High Frequency Sample
-No Low Pass Filter
25. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 25
PeakVue Case Study – Outer Race Defect
359 RPM
Peak Impact Detection registersEnveloping registers (Demodulation)
26. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 26
Five Inputs / Eight Live Plots
Five Inputs:
Channel 1
Channel 2
Channel 3
Channel 4
Plus Tachometer
8 live plots
27. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 27
Patented Emerson Triax = Easy and Fast! Fast
28. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 28
Where to Use Triax or 4 Channels?
• Everywhere in Route Mode
– Easier
– Faster
Example: Paper Plants (dryer section)
• Turbines Start-up (need to see phase info at both planes, so 4 Channels+Phase)
• All Advanced Applications Where Cross Channel Data is Needed
Fast
Advanced
Advanced
29. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 29
SpeedVue = Easy and Fast Fast
Measure rotating speed
without reflecting tape?
Yes, it is possible!
Laser speed sensor
Measure surface shape of shaft
Calculates the rotation speed
30. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 30
In Field Analysis
• Colored parameter alarms, provide
immediate indication of Machinery
Health
• See what parameter is in alarm and its
severity immediately at the point of
data collection
• Fault Frequencies help identify the
source of the vibration
• Fault Frequencies help identify the
source of the vibration
Parameter Alarms
Fast
Fault
Freq
A A A A B B B B
Fault Frequencies
Fault
Freq
A A A A B B B B
M1H - RPM
May 2007 – July 2007
Ampl: 1713.47 June 12 2007
Next
Trend
Prev
Trend
Trend
31. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 31
Analysis Tools in the Field
• Analysis Experts are preconfigured so even a novice can use them.
• Allows troubleshooting tests to be performed while next to the
machine without making a return trip
Advanced
32. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 32
Four Voltage Channels + Tachometer
Dual Orbits!Dual Orbits!
Advanced
34. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 34
Four Voltage Channels + Tachometer
andand
Four AccelerometerFour Accelerometer
Channels + TachometerChannels + Tachometer
Advanced
35. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 35
Transient analysis
Analyze the detailed spectrum and
waveform by sliding of interest bar
Advanced
36. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 36
Laser Shaft Alignment
Use my analyzer tool for
simple & advanced Shaft Alignment?
Yes, it is possible!
Via Bleutooth Communication
Basic and Advanced Modes
- Add compensation factors
- Full or Partial Sweep
Advanced
37. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 37
Single and Multi Plane Balancing
Advanced
Use my analyzer tool for simple &
advanced balancing jobs ?
Yes, it is possible!
Laser position sensor + tape
Acquire reference run data
Add or remove trail weights (plane 1, 2, etc)
View balance correction
Collect trim run data for corrected condition
38. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 38
Cross-Channel Phase
Check for Misalignment
– Measure across a coupling
– Check phase at running speed
Advanced
39. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 39
Structural Analysis Options
Advanced
• Operating Deflection Shape
– Performed while machine in operation
– Single frequency (typically running speed) measurement
– Can be performed with any CSI machinery analyzer
– Four channel is recommended
– Measures actual amplitude of deflection
– Shows how machine deflects in normal operation
• Modal Analysis
– Requires machine to be shut down
– Analysis across all frequencies
– Requires dual or four channel CSI 2140 for measurements
– With 4 channels: 1 channel is reference + triax
– Determines ratio of response to input, no absolute amplitudes
– Detailed model of machine stiffness, resonances, etc.
40. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 40
ODS on Piping
• Triax sensor + ODS offers more
locations to collect data
• Due to Triax no more Software
interpolation required
Advanced
41. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 41
Some other ODS-examples
Advanced
42. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 42
Modal Analysis or Coherence Case History
• Verify if vibration is related across points
• Reoccurring failure on paper machine
– Unusual vibration present
– Matched turning speed of pump below
• Coherence measurement
– proved that vibration was related
• Fixing pump operation
– solved paper machine problems
Advanced
43. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 43
Resonance
• Natural frequencies are directional
• So, you need to measure in Horizontal, Vertical and Axial direction.
• With CSI 2140, all directions can be measured simultaneously
• For hammer impact tests, your hammer is channel 4
Advanced
MOTOR
44. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 44
Impact Test Application
• Structural Analysis
– Identify resonances
– Measure stiffness
– Determine system response
– Modal analysis
• Use One Hammer and Three
Accelerometers
• Use One Hammer and One Triax
Sensor
MOTOR
Advanced
47. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 47
00998877665544332211009988776655443322110099
Thin Profile
66554433 mm
48. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 48
Built-in Stand
49. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 49
Comfortable New Strap
50. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 50
Communications
Ethernet Port
Wi-Fi to AMS
Machinery Manager
Bluetooth to
accessories
Ethernet
USB 2.0
Wi-Fi
Load Routes
using USB
Memory Stick
51. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 51
Remove Wires to Increase Safety
>>>>>>>>>>>>>> >>>>>>>>>>>>>>
Customer Quote:
“The fact is, today none of my vibration techs
would do a route without headphones.”
Customer Quote:
“The fact is, today none of my vibration techs
would do a route without headphones.”
52. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 52
E-mail Route/Data Files
• Upload data to local PC with FREE
software
• E-mail, FTP, or copy across network
from remote location to database or
SME for archive and analysis
53. Introduction to Portable Vibration Analysis • Emerson Confidential • 5/10/2015 • Slide 53
Li-ION Battery - Full 10 Hour Shift
External Charger
8 Hr
24 Hr
Car Charger
Simultaneous 4-channel measurements on the CSI 2140 can be used almost anywhere. From speeding up routing data collection with a triaxial accelerometer to more advanced troubleshooting tests like transient, cross channel, dual orbits, ODS/Modal, etc.
L1 - weakening of metal, no pits
L2 - Small pitting/holes
L3 - clear indication
L4 - going to fail within days/weeks
L5 - machine failing
Four accelerometer/voltage channels plus phase input really makes it a five channel instrument. Some other brands of vibration analyzers can only do 3 channels plus phase or four channels without phase.
The large 7.5” diagonal, full VGA resolution, color screen allows for easy and useful display of up to 8 live plots so the user can see the data as it is being collected from each of the four channels.
Using the 4-channel input adapter the user can monitor sleeve bearing machines with the 4-channel volts measurement plus phase for dual orbit plots to monitor shaft movements
In addition to monitoring rolling element bearings, the 4-channel CSI 2140 is also excellent for monitoring sleeve bearings to get dual orbits from the displacement probe signals through the protection system rack.
Turn the 4-channel input adapter over and the user can rolling element bearing machines with the 4-channel accelerometer measurements plus phase for cross channel phase, transient, ODS Modal, and much more.
An area of
An easy test for misalignment is to measure cross channel phase across the coupling of a machine. If the cross channel phase across the machine is 180 degrees plus or minus 30 degrees then misalignment is a probable fault condition.
Coherence can be used to see if the vibration that is being measured is actually coming from the machine being measured or from another source like a nearby neighbor machine.
The screen is 13X brighter than the CSI 2130 screen and can easily be seen outdoors in bright sunlight. The touchscreen works with gloves. The keypad is backlit for easy visibility in dark environments.
The CSI 2140 is much thinner than the CSI 2130 and comfortably fits in the hand for all day route data collection.
The built-in stand is useful for standing the CSI 2140 upright on the desk or out in plant when collecting longer transient, balance, or slow speed data.
The stand also works with the 4-channel adapter attached.
A wide, stretchable, non-slip neoprene strap for comfortable all day data collection.
The strap easily attaches or detaches to the CSI 2140 with the push of a button.
USB 2.0 is twice as fast as the CSI 2130’s USB 1.0.
Wired Ethernet or wireless Ethernet (Wi-Fi) can be used to directly communicate with the AMS Machinery Manager database across a corporate network without the need for AMS Machinery Manager on the local PC.
Users can listen to the vibration at the same time as watching the vibration plots with wireless Bluetooth enabled headphones to provide another dimension to analyzing machinery health.
No doubt — headphones add benefits to route-based analysis. But headphone cords that attach to the handheld analyzer can become a nuisance. But even more serious, cords present a safety risk by catching on machinery and endangering both the technician and the process.
Listen to the vibration signal for impacting sounds while you are watching the vibration plots during collection
Listening to the vibration while you are collecting the data and watching the vibration plots on the analyzer can allow the user to associate the sound with the data plots further add further clues to their investigation of machinery health.
Li-ION battery will last 10+ hours collecting 4 simultaneous channels and full backlight continuously.
The battery can be easily removed and swapped with a spare fully charged battery via the external battery charger.
A car charger accessory is available to charge the CSI 2140 battery while driving to your location.
1 GB of internal memory and up to 32GB SD cards mean virtually unlimited memory and no more return trips to the office to unload and reload the unit during data collection.