Protective Maintenance Fans Cement

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?

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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


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


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?


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


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


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


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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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


“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

Education

Protective Maintenance Fans Cement