Emerson Process Management - CSI

DoctorKnow Application Paper

Title: Unsolicited PeakVueTestimonial Source/ Bill Kilbey Author: Product: Data Collector/Analyzer Technology: Vibration Classification:Advanced

The following article was received unsolicited from a user at the Alcoa Warrick Operations and will be distributed in their company wide monthly corporate information letter. Jim Crowe writes: "We recently traded in our old CSI analyzers in on new 2120 analyzers here at Warrick Operations. We got one dual channel unit for each area and the rest are single channel units. The 2120 analyzers have two new options, SST and PeakVue, that are not in the 2110 or 2115 analyzers. The manual that you get with the unit does not have very much information on these options so when I attended CSI's Reliability Week I decided to attend the one day PeakVue class taught by Bill Kilbey. The PeakVue process measures the high frequency stress waves above the high pass filter chosen and brings them back down into the spectrum at the repetition rate which will correspond to the defect frequencies." "The first week I took some PeakVue readings on some of our bearings I found a bearing on an idler spindle that had over 20 G's impacting in the waveform. The regular route spectrum and waveform showed very little high frequency energy with only a .6 G swing in the waveform with a crest factor of 2.9. If you have a bearing defect it will emit high frequency, short duration stress waves. These stress waves are not detected due to the sample rate on regular route data. PeakVue always samples at 100,000 samples per second, and holds the highest amplitude, therefore you get the true amplitude. The PeakVue spectrum was showing peaks in the inner race, ball spin and slight outer race frequencies. The waveform in PeakVue has a true peak value, so I knew we had a problem. We were going to shut down the machine in two days for a routine PM so I got a replacement spindle built up and ready. After replacing the spindle unit we inspected the old bearings we had removed. We found the bearing had a spall completely around the inner race, some of the rollers had deep pits, and the outer race was just starting to spall. The failure was caused by excessive thrust loading due to a shim being left out of the spindle end cap. At first we just took PeakVue readings in the analyze mode and stored them to the database. I was wanting to get a feel for the value of the PeakVue process. I now take one PeakVue reading on each bearing on all of our critical equipment. They can be set up in regular route data and stored
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Emerson Process Management - CSI

and trended just like regular spectra and waveform. I do not analyze any slow speed equipment, but the instructor at CSI had an example of a bearing defect he found on a machine operating at two RPM. I believe this new technology will make bearing and gear defect detection a lot easier and more reliable." For more information on PeakVue training, Intermediate Vibration Analysis has more information and up to date examples. This is a great testimonial to the value of training and Reliability Week. All contents copyright 1998 - 2006, Computational Systems, Inc. All Rights Reserved.

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