Vibration analysis is used to determine if problems exist within a specific piece of equipment. By completing analysis of the vibration signature produced by a machine, faults such as unbalance, misalignment, bent shafts, mechanical looseness, faults in gear drives, defects in bearings and resonance can be detected. Using this information, the root cause of a vibration issue can be found and a path to correction can be presented.
Vibration analysis detects faults early when cost to repair is significantly less. A catastrophic failure results in equipment loss, unplanned downtime as well as increases potential for health/safety/environment issues. Removing the equipment from service on a planned basis results in reduced asset cost and a drastic reduction in unplanned downtime.
Typically vibration analysis is used as part of a predictive maintenance program (PdM). The most effective way this works is by comparing to certain industry base lines, but mostly by identification of changes over time.
Predictive Maintenance (PdM) – Using a combination of vibration, airborne ultrasound and infrared thermography equipment faults can be found within an equipment train. Identifying these faults prior to failure and replacing them on scheduled downtime significantly reduces operating and maintenance costs.
PdM – Typically teams of technicians provide daily monitoring of equipment condition with respect to vibration. Embedded into the plant, these teams work closely with plant maintenance personnel to help determine if a piece of equipment has a potential to fail prematurely. This work is typically completed in any plant that has rotating equipment.
Advanced Vibration Diagnostics – Many different projects have been completed for paper machine reliability with emphasis placed on machine speed ups. As machine speed is increased clients are interested in determining which components may pose a vibration related issue at the higher speeds. By providing recommendations for roll or component replacement as well as overall machine stiffening – increased reliability at these proposed speeds can be realized.
Examples of Vibration Analysis Project Successes
Paper Machine Press Pedestal Modification– Analysis of pedestal vibration and a designed/installed structural correction resulted in a reduction of 2 vibration induced bearing related motor changes per year down to none.
Pit Blast Vibration Assessment – How blasting adjacent to an induced draft ventilation fan at a mine had potential to negatively affect fan bearing and structural integrity. Looking at vibration signatures as measured on the fan, and fan base, while blasting is occurring resulted in recommendations for a blast frequency and proximity limit.
Forced Draft Fan Vibration Assessment – A large fan critical to plant operation displayed excessive vibration and premature bearing failures. Downtime due to this fan results in a loss of 1 million $ USD per day. Plant personnel could not determine the root cause of vibration. Advanced testing and analysis yielded a root cause and a path to correction was presented.
Can you tell how long a bearing will last with one reading?
Sometimes yes but only when the damage is already quite advanced. The most precise use is by monitoring the change. With that historical data we can then provide some insight as to how long the bearings could last.
Advanced diagnostics is a term used by Acuren reliability engineering services to define a series of tests, including visual assessments, vibration, linear displacement, dynamic pressure, and process data to obtain an ‘as is’ dynamic assessment of an asset.
Richarson Oilseed is one of Canada’s oldest and largest fully-integrated crushing, refining, processing and packaging operations. In the absence of timely manufacturer support for a critical equipment issue, the full time onsite Acuren Condition Monitoring Specialist was able to diagnose and provide a detailed correction path on a defective trunion bearing.
Acuren’s experts, knowledge and efficiency can be an essential part of evaluating critical pulp and paper facility assets such as boilers, digesters, piping, tanks, pressure vessels and rotating equipment.
Acuren’s engineering, inspection and industrial services teams consist of engineers, technologists and tradespeople with a diverse educational background, working in the mining industry for over 40 years.