Part 3 Condition Monitoring - Amazon S3 · 2016-07-21 · Condition Monitoring - Dynamic Continuously monitored dynamic performance parameters Continuous Condition monitoring can

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© Artec Machine Systems | 2016 Page 1

Reproduction by any means for any purpose prohibitied without written permission by

Artec Machine Systems

AGMA Webinar – 21 July 2016 – 1 pm

Prepared and Submitted by:

Artec Machine Systems26 Commerce Drive, North Branford, CT 06471

Part 3 – Condition MonitoringImportance / Parameters to Monitor / Periodicity

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Learning Objectives

A Gearbox Field Inspection Program:• What to monitor and observe• How to establish ongoing Maintenance Procedures to

extend the life of a gear unit• How to avoid extensive collateral failures

This is not a design forum.

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We bring to you this AGMA Webinar Series:

Gearbox Field Inspections – Part I : Load Distribution

Gearbox Field Inspections – Part II : Lubrication

Gearbox Field Inspections – Part III : Condition Monitoring

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AGMA has several references to condition monitoring that can be useful in setting up an inspection program. While there are several standards written for a specific application group the suggestions are generic for many types of gear services:

AGMA 919-1-A14 - Condition monitoring and diagnostics of gear units and open gears. Part 1 – Basics.

AGMA AWEA 921-A97 Annex G – Recommended Practices for Design and Specification of Gearboxes for Wind Turbine Generator Systems

ANSI AGMA AWEA 6006-A03 Annex F - Standard for Design and

Specifications of Gearboxes for Wind Turbines

ANSI AGMA 6015-A13 Annex K - Power Rating of Single and Double Helical Gearing for Rolling Mill Service

Some AGMA Reference Material

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Condition Monitoring

What is it?

Condition monitoring is the process of monitoring a parameter(s) of

behavior over time which may show a pattern indicative of developing

issues. Often referred to as trending.

The use of condition monitoring allows

maintenance to be scheduled, or other

actions to be taken to prevent failure

and avoid its consequences.

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To be effectively implemented, a condition monitoring

program should have the support of not only the

maintenance, operational and engineering

departments, but also executive management.

Condition monitoring

Who is involved?

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Maintenance StrategiesA foundation…

1. Reactive Maintenance

Run to Failure

2. Preventative Maintenance

Based on time or hours

3. Predictive Maintenance

Based on Actual Condition

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Risk Mitigation Through Regular Condition

Monitoring and Subsequent Maintenance

A B EDC FNEW

Condition without service

Condition with service

Extend the overall

service life through

regular maintenance

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Equipment Priorities

Priority A – Equipment essential to production process. Business cannot survive should downtime occur. Generally continuous service without installed spare equipment. AKA “Special Purpose”.

Priority B – Redundant equipment. Usually spared or noncritical service. AKA “General Purpose”.

Priority C – Highly redundant equipment. Interruption of operation for several days is acceptable. Hardly any impact on the production process.

We will primarily be discussing Priorities A during this presentation.

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Critical items to the Condition Monitoring Process

Establish a baseline Consistent measurements and samples Comparison of data collected to baseline

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Importance of Establishing a Baseline

Simply put the Baseline is a starting point used for comparisons.

Since condition monitoring is concerned with relative change, the starting point must be established. One data point is NOT monitoring.

It is important to obtain baseline information as soon as physically possible after start up of the equipment or after this slide is presented to you.

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Condition MonitoringThe two basic groups

Dynamic

Static

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Condition Monitoring - DynamicContinuously monitored dynamic performance parameters

Continuous Condition monitoring can provide useful information on

the health of the gears and bearings in a gear system. This could

include the following:

Sensory Inspection: touch, sound & smell

Temperatures: ambient, lubricant, bearing

Lube oil: supply pressure & flow

Acoustic Emissions (Sound)

Speed

Shaft Vibrations

Housing Vibration

Torque/Load

Lubricant Analysis

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Touch oftentimes can be the

first rudimentary indication of

an operating problem. Placing

your hand on a the gear

housing or on a bearing cap

can sometimes verify a gear

unit is operating at an

elevated temperature. This is

an age old check as the feel

of a hand can usually sustain

50-60C (122-140F) for a

limited period of time.

Condition Monitoring - Dynamic

Touch

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Temperature: Ambient

Considering the ambient temperature for a condition

monitoring program is very important for gear units

operating in an open air environment. Seasonal variations

and length of the day can alter the gear unit operational

temperature considerably. For the purpose of monitoring

the unit’s condition, recorded values over time with these

variables are needed. Then a historic comparison can be

observed with the change of season.

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Temperature of gear units including lubricant, housings,

and bearings is one of the most critical parameters to

observe.

Temperatures should be measured during startup with

proper lubricant levels as well as under steady state

conditions when the gear unit has established thermal

equilibrium. The highest temperature measured should

be considered the baseline value.


Temperature: lubricant, housing, bearings

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Temperature monitoring - Types of Devices

Bimetallic thermometers

use the expansion

differences of dissimilar

metals or alloys in

contact with a single

temperature

Infrared Thermometer

(handheld) – detects

emitted IR energy from

the surface to

determining temperature

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Temperature monitoring - Types of Devices

RTDs – resistant

element, often platinum

Thermocouples – measure

voltage potential across 2 wires

Imaging camera – detects emitted

IR energy from the surface to

determining temperature.

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Example of bearing temp Alarm and Shutdown definition

Example Value

Measured 80°C

Alarm 90°C

Shut down 100°C

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Pressure

Pressure switches

Pressure Gages

Pressure Transmitters

Pressure Regulators

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Flow

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Sound is a vibration that propagates as a typically

audible mechanical wave of pressure and

displacement, through a medium such as air or water.

Monitoring sound measurements can be a complex

matter depending on a series of variables if any value

is obtainable. Ambient background, variations of

ambient conditions such as time of day and load will

alter recorded data appreciably.


Sound

https://en.wikipedia.org/wiki/Vibration

https://en.wikipedia.org/wiki/Mechanical_wave

https://en.wikipedia.org/wiki/Pressure

https://en.wikipedia.org/wiki/Particle_displacement

https://en.wikipedia.org/wiki/Transmission_medium

https://en.wikipedia.org/wiki/Air

https://en.wikipedia.org/wiki/Water

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It is assumed the gear unit as delivered into service has been

appropriately successfully tested at the gear vendor’s shop. This may

or may not have included a sound frequency test. Nevertheless its

performance will produce noise normal to its operating design.

What is noise?

Noise is unwanted sound. This results in a judgement call applying

discretion between sound and noise, where any sound may be

considered noise. Unwanted sound, changes in sound maybe a

determining factor whether there is something wrong with a gear unit.


Sound

https://en.wikipedia.org/wiki/Sound

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Sound Power is the force on a surface where the sound energy is

emitted measured in watts. Unlike sound pressure it is not location

dependent rather the power emitted at the source.

Sound Pressure is the periodic pressure variation produced by the

sound wave resulting in a hearing sensation caused by the pressure

variation measured in decibels.

As a practical application condition monitoring references are in sound

pressure units.


Sound

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A-WEIGHTING - dBA

Follows the frequency sensitivity of the human ear at low levels. The most

commonly used weighting scale, as it well predicts the damage risk of the ear. A-

weighting scaled meters will filter out much of the low-frequency noise, similar to

the response of the human ear.

B-WEIGHTING - dBB

Follows the frequency sensitivity of the human ear at moderate levels, used in the

past for predicting performance of loudspeakers and stereos, but not industrial

noise.

C-WEIGHTING - dBC

Follows the frequency sensitivity of the human ear at very high noise levels. The

C-weighting scale is flat, and therefore includes much more of the low frequency

range of sounds than the A and B scales.

Today nearly all noise measurements for hearing conservation are measured in

dBA resulting in misapplications and errors when figuring attenuation from hearing

protectors.


Sound - Weighting

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• Establish Trending data

• Measurements should be taken 1 to 3 meters

from source (not directly at the source)

• Take measurements in at least 2 repetitive

locations preferably from vertical surfaces of the

gear unit

• Gear unit should be fully/partially loaded > 60%

© Artec Machine Systems | 2014


Sound Level Meter – Method of Diagnostics

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Microphone location

The microphone should be located perpendicular to one of the unit’s major vertical

surfaces, near the approximate center but not less than 1.0 foot (0.3 meter) above the

mounted surface of the gear unit. (see figure ).

The distance between the

major vertical surface of the

gear unit and the microphone

a distance such as the

normal working distance of

an employee but not less

than one meter.

Ref AGMA 6025-D98 fig 1


Sound Measurement

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Corrections for background noise

It is apparent if the ambient sound level is not appreciably lower than

the gear unit a field measurement monitoring program is not possible.

For example a gear unit train operating in an environment with other

running machinery. Nevertheless human senses are the most

versatile instruments one can employ. Tooth contact verification is a

visual check. Smelling the oil for changes in odor is a check. And

likewise hearing a gear unit operating can be a reliable sound check.


Sound - Corrections

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Corrections for background noise

If it is necessary to take account of background noise, correction values, at each

measurement point should be chosen. The correct value depends upon the difference

in dBA between measurements and the background noise measurements.

Corrections values for background noise

Difference between gear unit Correction to be subtracted from

and ambient SPL in dBA the gear unit source SPL in dBA

3 3

4 to 5 2

6 to 9 1

10 or more 0


Sound

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What to hear

There is much one can do to execute a sound check.

Remember sound is what you hear. Noise is sound you do not

want to hear.

Possibly you may have experienced listening to a gear unit that just does not

sound right. Or sounds different. So you shutdown to inspect the gear set. This

sense can be useful.

Record the number of teeth of each rotor.

Listen for any change in sound. Has it changed?

Is it a periodic attenuation of the normal sound level?

Is it synchronous with any meshing frequency?

Is it a multiple of any rotating frequency?


Sound

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Key Phasor


Speed

Laser Tachometer

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Vibration Analysis

Two Main types of condition monitoring

Vibration

Continuous vibration monitoring

High or low magnitude of value

monitored

Periodic vibration analysis

Frequency spectrum analysis etc

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Condition Monitoring – Dynamic

Vibration Sensor Types

Vibration (shaft, GMF, bearings)

• Displacement

• Velocity

• Acceleration

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Typical vibration probe, key phasor arrangement

Vibration probe

Key phasor

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Casing Accelerometers

Casing Accelerometers maybe judged according to ISO 8579-2

standard (1993)

Here are some general recommended settings

Indication from the acceleration probe "PEAK" values:

A(max)< 8 g

A(Alarm)=14 g

A (shutdown)=20 g

A low pass filter of at least 10'000 to 20'000 Hz must be used

(depending on tooth frequency and natural frequency of the

probe).

To set the Alarm/Trip value as above.

2 times gear mesh frequency and above typically exhibits low

energy even at higher G values

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Zone A: Values, which are usually measured after start-up of a new machine.

Zone B:Installations with these values can usually be operated without any limitations.

Zone C:Installations with these values should not remain in continuous operation. The

drives should be generally overhauled and/or further investigations undertaken.

Zone D:Installations with these values are at risk and should be shutdown. A general

overhaul is necessary.


Gearbox Diagnostics / ISO 10816

Measuring and Analyzing acc. ISO 10816 - 3

And defining acceptance criteria

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ISO 10816-3 Vibration Severity Chart / Reasonable Limits

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Vibration Analysis

Vibration analysis is a powerful tool that when

integrated into an overall inspection program will help

save maintenance costs by:

1. Reducing the risk of unexpected downtime

2. Extremely effective safeguard against total loss

3. Timely ordering of replacement parts to reduce

expediting costs

4. Advance planning shortens repair and inspection times

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Some of the specific types of problems which cause vibration

which can be detected in an analysis:

Roller Bearing defects or wear

Damaged or worn teeth

Misalignment; internal or external

Rotating looseness or imbalance

Resonance, loose components

Bending or eccentricity

Unequal thermal effects

Bad (worn/misaligned) belt drives


Vibration Analysis

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Instituting a Routine Vibration Monitoring Program

Pre visit preparation; determine bearing, and gear kinematics, study gear layout, program vibration route…

initial visit establishes a baseline, preferably under a loaded condition

Subsequent visits are compared to the baseline and establish statistical alarm / warning limits

Each set of measurements are analyzed for frequency, phase, and amplitude

All amplitudes are compared to suggested standards established by (ISO) International Standards Organization, API or OEM.


Vibration Analysis

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Required data for vibration analysis

• Shaft speeds

• Gear mesh frequency

• Driver/Driven associated frequencies

• Bearing frequencies

• Multiple Bearings

• Multiple Meshes

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Vibration Analysis - Kinematics

Gear Kinematics can be calculated from the number of teeth and the type of gear.

Simple parallel or right angle gears are the number of teeth times shaft rotation to

get the GMF gear mesh frequency

Epicyclical gears have formulas that depend on fixed and rotating components

GEAR MESH FREQUENCY: number of teeth X shaft rotation

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Gearbox Diagnostics


roller count BPFO BPFI FTF BSF

23232 EAS.M 18 7.63 10.37 0.42 3.13

23232CC W33 18 7.76 10.23 0.43 3.47

23236CC W33 19 8.23 10.76 0.43 3.58

231SM300MA 7.82 10.17 0.43 3.68

BPFO – Ball Pass Frequency of the Outer race (frequency created when all the rolling

elements roll across a defect in the outer race)

BPFI – Ball Pass Frequency of the Inner race (frequency created when all the

rolling elements roll across a defect in the inner race)

FTF – Fundamental Train Frequency (frequency of the cage)

BSF – Ball Spin Frequency (circular frequency of each rolling element as it spins)

Bearing Kinematics are available from the manufacturer (see chart above)

The frequencies in this chart are base on running speed (orders) to calculate the

actual frequency multiply by the shaft speed.

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Kinematics KPU-210

Timken Bearing

Sun z = 23

planets z = 41

annulus z = 103

Pinion z = 17

Bevel wheel z = 37

sun z = 23

planets z = 35

annulus z = 91

Spherical Roller bearing

Axial bearing

Axial bearing



Timken Bearing


Timken Bearing



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Typical measurement points for reducer

gearbox with anti friction bearings

Pick up point 11

blue, vertical

Pick up point 9

yellow, vertical

Pick up point 1

yellow, horizontal

Pick up point 3

blue, horizontalPick up point 4

white, horizontal

Pick up point 7

blue, vertical

Pick up point 6

red, vertical

Pick up point 8

white, vertical

Pick up point 2

red, horizontalPick up point 10

red, horizontalPick up point 12

white, horizontal

Pick up point 5

yellow, horizontal



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Vibration Sensor Selection Guidelines

Displacement probes:

At lower input speeds, and at all speeds when hydrodynamic bearings,

such as journal or tilting pad bearings, are used, vibratory displacement

units and proximity probes are commonly used.

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Vibration Sensor Selection Guidelines

Accelerometers or Velometers:

• On rolling element bearings are used to track the vibration of the

lower shaft orders, referenced as first (1st), second (2nd), third (3rd)

and fourth (4th) orders, typically, are analyzed using units of velocity.

• At higher shaft speeds, and on housing measurements of units with

hydrodynamic bearings with high gear mesh frequencies, vibratory

acceleration units may be preferred, depending on the specific

application.

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Continuous Control Panel (HMI)

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Condition Monitoring – DynamicSingle sensor trend plot

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Torsional Displacement can be measured by probe or laser

• Input motor torque correlated with the applied motor

current

• Measures Torque and fluctuations

• Linear vibration trending methods applied to torsional

vibration

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Torque

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No. Symbol Signal

1 Speed

2 Shaft vibration

8 Acceleration uniaxial

1 Torsion

6 Temprature

Condition Monitoring System – CMS für KPBV + COPE


Complete monitoring system: example

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Operating Range

Operating Data Monitoring

Normal operating range Gearbox performs well and operates normally.

Caution range Gearbox may still be operated however continuous trend monitoring must

be adhered to.

Depending on the fault, further actions such as power reduction or shut

down may be required.

Danger range Danger for man and machine

Any operation within this range is forbidden.

If the system does not stop automatically, stop it immediately!

Low Low Low High High High

Danger range Caution range

Normal

operating

range

Caution range Danger range

Example:

for pressure, temperature, speed or level range. Can be adapted for many other parameters

power draw, torque, vibration, oil contamination…

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Typical operating parameters & set-points for alarm / shutdown

Setting points of instruments

MFR (Model) / SN XXXXXXX

Pos. DescriptionFAT

Measured

Installed

MeasuredAlarm Shut Down

T1.1 RTD, radial bearing, pinion 77.56°C ~ 98°C 108°C 113°C

T in RTD oil inlet 50°C 50°C 70°C 75°C

V21 Radial vibration, pinion vertical 10.41 µm ~ 6.5 µm 86 µm 111 µm

V31 Axial displacement, wheel - 275.5 µm - 180 µm - 500 µm - 600 µm

V32 Axial displacement, wheel ~µm - 170 µm + 500 µm + 600 µm

V42 Speed, wheel 5209 rpm 4438 rpm

V45 Casing Vibration 5 mm/s 5 mm/s 15 mm/s 22 mm/s

P34 Oil Inlet Pressure 1.5 bar 1.5 bar 1.2 bar 1.0 bar

F35 Flow 470 L/min

470

L/min

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Trend analysis provides the best indication of health for

oil samples.

Trend analysis uses the historical oil sample results as

the basis for normal test results. A trend is established

by repeated oil sample results from the same machine.

Three to five oil samples are needed to establish a

baseline

Oil hours and equipment hours must be correct for

effective trend analysis

Every effort should be made to correctly fill out the

sample label

Lubrication

Baseline Establishment

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RackFRI-6-HY -

0916

T UE -13-HY -

0830

W E D-9-HY -

0803

T UE -11-HY -

0614

W E D-7-HY -

0518

FRI-7-HY -

0325

T HU-8-HY -

0224

W E D-9-HY -

1222

T HU-12-HY -

1125

T HU-9-HY -

0909

Lab Number 1710172 1706109 1700621 1689977 1684637 1673248 1667291 1654804 1649309 1632463

SIF No PC -? PC -? PC -? PC -? PC -? PC -? PC -? PC -? PC -? PC -?

TestPkg 2-Mar 2-Mar 2-Mar 2-Mar 2-Mar 2-Mar 2-Mar 2-Mar 2-Mar 2-Mar

Sample Date 8/26/2011 8/18/2011 7/23/2011 6/2/2011 5/4/2011 3/4/2011 2/7/2011 12/17/2010 11/16/2010 8/25/2010

Fluid

Typical |

Base PE438 PE438 PE438 PE438 PE438 PE438 PE438 PE438 PE438 PE438

DiagName BILLQ BILLQ KEVIN KEVIN KEVIN KEVIN KEVIN KEVIN KEVIN KEVIN

ImgColor

Fe 15 | 30 1.6 1.7 1.7 1.7 1.7 1.8 2 1.9 1.9 1.9

Cr 4 | 8 0 0 0 0 0 0 0 0 0 0

Mn 0 0 0 0 0 0 0 0 0 0 0

Ni 2 | 5 0 0 0 0 0 0 0 0 0 0

Ti --- | --- 0 0 0 0 0 0 0 0 0 0

TAN 0 | 0.04 0.05 0.059 0.06 0.09 0.05 0.04 0.03 0.03 0.03 0.03

Kv@40°C 34.9 | 34.0 34.3 34.1 34.5 33.7 34 34.2 33.9 33.9 34.5 33.8

Kv@100°C 6.3 | 5.59 5.5 5.6 5.5 6.3 6.4 6.5 6.4 6.4 6.5 6.6

Grade ISO 32 ISO 32 ISO 32 ISO 32 ISO 32 ISO 32 ISO 32 ISO 32 ISO 32 ISO 32

VI | 110 93 101 92 139 142 146 143 143 144 154

Img MPC

>4µm(c) 2µm --- 159 461 413 680 346 133 471 977 681 3797

>6µm(c) 5µm 640 78 182 83 173 89 29 108 209 137 402

>14µm(c) 15µm 80 24 52 6 15 8 4 14 21 11 33

>200µm 0 0 0 0 0 0 0 0

ISO Code 16/13 13/12 15/13 14/10 15/11 14/10 9-Dec 14/11 15/12 14/11 16/12

ImgBottom

White Metal NONE NONE VLITE NONE NONE VLITE VLITE VLITE NONE NONE

Babbitt NONE NONE NONE NONE NONE NONE NONE NONE NONE NONE

Precipitate NONE NONE NONE NONE NONE NONE NONE NONE NONE NONE

Silt NONE NONE NONE NONE NONE NONE NONE NONE NONE NONE

Debris NONE NONE NONE NONE NONE NONE NONE VLITE NONE NONE

Dirt NONE NONE NONE NONE NONE NONE NONE NONE NONE NONE

Appearance NORML NORML NORML NORML NORML NORML NORML NORML NORML NORML

Odor NORML NORML NORML NORML NORML NORML NORML NORML NORML NORML

H2O(Emul) NEG NEG NEG NEG NEG NEG NEG NEG NEG NEG

H2O(Free) NEG NEG NEG NEG NEG NEG NEG NEG NEG NEG

Condition Monitoring – DynamicOil-Sample trending spreadsheet

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Condition monitoring can provide useful information on the health

of the gears and bearings in a gear system. This could include the

following:

Sensory Inspection: Smell & Visual

Structural inspection

Tooth contact check

Bearing accuracy check

Alignment

NDT

Alignment problems, micropitting and cracks are examples of

distress that are difficult or impossible to detect while the gear unit

is in operation.

Condition Monitoring - StaticStatic monitoring parameters – gear unit not in operation

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Odor test

Carefully sniff the oil sample. Compare the

smell of the used oil sample with that of

new oil. The used oil should smell the same

as new oil, that is, it should have a bland,

oily odor. Oils that have oxidized have a

“burnt” odor, or smell acrid, sour or

pungent.

Ref AGMA/AWEA 921-A97 ref G.4.2.2

Condition Monitoring - Static

Smell

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Visual structural inspection

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Tooth Contact Pattern – Double helical gear

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Tooth Contact Pattern – Single helical gear

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Clearances higher than specified:• Hydrodynamic Bearings –

• High vibrations• Tooth contact issues

• Roller bearings –• Tooth contact issues


Bearing clearance check

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Alignment can be influenced by: Cracks in case Foundation issue Bearing clearance


Alignment

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Non Destructive Evaluation

Dye Penetrant

MPI

Magnetic Particle

Inspection

Ultrasonic (sub surface discontinuities)

https://www.google.com/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0ahUKEwjU2c6N_f_NAhVJbz4KHXWwDugQjRwIBw&url=http://rope-access.co.za/services/dye-penetrant-inspection/&bvm=bv.127178174,d.cWw&psig=AFQjCNE1OSs8V07oaAxtl1wSW9Mg7C8euQ&ust=1469033146770606

https://www.google.com/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0ahUKEwjU2c6N_f_NAhVJbz4KHXWwDugQjRwIBw&url=http://rope-access.co.za/services/dye-penetrant-inspection/&bvm=bv.127178174,d.cWw&psig=AFQjCNE1OSs8V07oaAxtl1wSW9Mg7C8euQ&ust=1469033146770606

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Photography

DSLR – digital single-lens reflex camera

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Photography

Digital Magnifying Camera

50x Zoom Type Lenses are great

tools for analysis of surface defects.

The resolution is great. It is portable

with the use of a laptop and very easy

to install and operate hardware. One

can use it on curved surfaces and roll

it to produce a series of pics of

contoured surfaces. Very light and

portable.

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Photography

Digital Magnifying Camera – 50x

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Reporting

Key Data for Record Keeping, Trending and Observation

• Conclusion / Recommendation

• Reason for Outage

• Situation of the Installation

• Work Carried Out / Findings Results

• Remaining Work

• General Remarks

• Parts on Hand

• Replacement parts

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Reporting

Record Keeping, Trending and Observation

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General Maintenance Schedule Guideline for Gearboxes

Not Gearbox Specific! Guideline only!Maintenance schedule for Gearboxes (General recommendation, not plant specific)

Daily or permanently

Weekly

After the first year of operation

Annually or every 8'000 operating hours

Every 20'000 operating hours


As required (special)

Description of work Remarks

Gearbox

Check drive groupe for leaks X X X X X X X

Check rotors visually X X X X X

Check load tooth bearing pattern on toothing X X X X X

Check and retighten gearbox anchoring X X X X X

Check all important bolt connections X X X X X

Check tooth contact pattern (blue ink test) X X X X

Check alignment of gearbox - driving machine X X X X In uncoupled condition

Check alignment of gearbox - driven machine X X X X In uncoupled condition

Dismantling and inspection of all gearbox parts X X

Lubrication and monitoring system (if applicable)

Record operating data X X X X X X X In operating condition

Check operating data X X X X X X X

Check oil level X X X X X X X

Check p of lub oil filter (if not monitored) X X X X X X X Indication

Check lubrication unit for leaks X X X X X X X In operating condition

Check all important bolt connections X X X X X X

Lube oil filter check, clean or replace if required X X X X X According to supplier

Check lube oil for water content / contamination X X X X X

Analyse lube oil X X X X X By customer / supplier

Check of instruments and interlocks X X X X According to supplier

Record and check setting points X X X X

Check and clean lube oil cooler X X X X According to supplier

Air filter check, clean or replace if required X According to supplier

Lube oil change (according to analysis) X According to supplier

Maintenance of components (motors, instruments, etc.) X According to supplier

Maintenance of components (valves, instruments etc.) X According to supplier

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General Maintenance Schedule Guideline for Gearboxes

Not Gearbox Specific! Guideline only!Maintenance schedule for Gearboxes (General recommendation, not plant specific)

Daily or permanently

Weekly

After the first year of operation

Annually or every 8'000 operating hours



As required (special)

Description of work Remarks

Gearbox

Check drive groupe for leaks X X X X X X X

Check rotors visually X X X X X

Check load tooth bearing pattern on toothing X X X X X

Check and retighten gearbox anchoring X X X X X

Check all important bolt connections X X X X X

Check tooth contact pattern (blue ink test) X X X X

Check alignment of gearbox - driving machine X X X X In uncoupled condition

Check alignment of gearbox - driven machine X X X X In uncoupled condition

Dismantling and inspection of all gearbox parts X X

Lubrication and monitoring system (if applicable)

Record operating data X X X X X X X In operating condition

Check operating data X X X X X X X

Check oil level X X X X X X X

Check p of lub oil filter (if not monitored) X X X X X X X Indication

Check lubrication unit for leaks X X X X X X X In operating condition

Check all important bolt connections X X X X X X

Lube oil filter check, clean or replace if required X X X X X According to supplier

Check lube oil for water content / contamination X X X X X

Analyse lube oil X X X X X By customer / supplier

Check of instruments and interlocks X X X X According to supplier

Record and check setting points X X X X

Check and clean lube oil cooler X X X X According to supplier

Air filter check, clean or replace if required X According to supplier

Lube oil change (according to analysis) X According to supplier

Maintenance of components (motors, instruments, etc.) X According to supplier

Maintenance of components (valves, instruments etc.) X According to supplier

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Record Keeping

Data Trending is only as good as the bookkeeping

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Basic Inspection Needs

Reference Information

Gear Manufacturer

Year & model

Gear serial and model #s

Service history & maintenance record

Upgrades or alterations

Spare parts in stock held by the owner

Servicing dealer information

Annual operating hours log

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Typical Maintenance Plan

Determine Maintenance Scheme

Your company employees, supplier, service center or combination

Set Schedule for Maintenance of Gear (refer to gear manufacturer

manual & maintenance scheme)

Daily, Weekly, Monthly, Yearly

Set up Parts Inventory for Your Facility

What do you need vs. what don’t you need

Work with Service Center & other Operators – save costs

Keep Daily Log

Note and make necessary repairs ASAP

i.e. Leak will effect additional repairs if not addressed

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Question and Answer

sub-presentations/question-answer-series-I.pptx

sub-presentations/question-answer-series-I.pptx

Documents

Part 3 Condition Monitoring - Amazon S3 · 2016-07-21 · Condition Monitoring - Dynamic Continuously monitored dynamic performance parameters Continuous Condition monitoring can