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e all know what a great job vibration analysts perform. They are all that stands between a manageable plant and the chaos and mayhem that can result from machines failing unexpectedly. It takes skill, knowledge and experience to be a good vibration analyst. But in many cases, the vibration analyst is only delivering half of the benefits they are capable of. Detecting faults so that catastrophic failures can be avoided is important, but what about avoiding the fault in the first place? If a machine was balanced, aligned, lubricated and operated correctly, and if all the issues related to installation and commissioning were attended to, then a plant would see far fewer fault conditions develop. The vibration analyst may not be responsible for all or, in some cases, any of these issues, but there is a great deal that an analyst can do to ensure that these issues are taken care of. In this article we will explore how the analyst can make a difference.
ACCEPTANCE TESTING
In addition to demanding reliability in purchased or repaired machinery, a testing regime must also be specified. As a minimum, specify maximum vibration amplitudes and do not accept the equipment unless it passes the test. The acceptance test specification will likely need to also specify the operating speed and load under which the test is performed, and the test may need to be performed at your site (if the vendor cannot reproduce the operating conditions).
RELIABILITY SPECTRUM
We believe that the reliability spectrum (see Figure 1) represents all of the areas where an analyst can be involved to improve the reliability of rotating machine in the plant. Lets start from the left and deal with each issue, one by one.
CONDITION MONITORING
Continued from page 8 why the machines need to be operated correctly. The analyst may not be involved with installing bearings, setting belt tension, and so on, but again, the analyst can provide valuable feedback so that the people who perform that work do understand how to do it correctly, and the importance of doing it correctly. looseness, misalignment, resonance and a wide variety of other conditions are often overlooked because it is believed that these conditions (unless extreme) will not cause the machine to fail. Instead, the analyst uses (often limited) bearing detection techniques and simply waits until the bearing shows sign of wear; and then action is taken at the latest stage possible. As already stated, if the other conditions, such as unbalance, misalignment and resonance were detected and corrected at an early stage, the analysts would see far fewer bearing faults and the organization would save a great deal of money (and the safety record would also improve).
REPORT GENERATION
One of the reasons why many condition monitoring programmes fail is the weakness of the reporting process. These are just some of the problem areas: 1. Reports are unclear they do not clearly state what is wrong with the machine nor do they indicate the urgency of the recommended maintenance action.
Figure 2: Laser alignment a key part of a reliability improvement programme
2. Reports are not accessible by the people who need them it is essential that all decision makers and other affected parties are informed about machine condition at the appropriate time. 3. Reports dont utilize all of the available data data from oil analysis, motor current analysis, infrared analysis and the ultrasound programme should be used to provide one, integrated, informative, actionable report.
LUBRICATION
Correct lubrication has such a dramatic effect on the reliability of the machine that it simply cannot be overlooked. The vibration analyst may not be involved in the lubrication process, or the analysis of the lubricant, but as with other areas of the reliability improvement programme, the vibration analyst must at least be another voice that continually stresses the need for machines to be lubricated correctly. Lubricants must be selected, stored, and dispensed correctly, and contamination must be minimized. It is also critical to periodically check whether the lubricant is still fit-for-purpose, and that there are no signs that a fault condition has developed.
CONCLUSION
Monitoring the condition of rotating machinery with vibration analysis is an essential part of any cost reduction (and safety improvement) programme, but the best results are achieved with the condition is improved. An investment may be required to make the necessary improvements, but employee job satisfaction (and safety) and corporate profitability will be the beneficiary. Dean Whittle, tel/fax: +44 (0)1206 791917 dean@rms-reliability.com Jason Tranter, tel: +61 3 5989 7285 jason@mobiusinstitute.com
CONDITION MONITORING
Obviously the condition monitoring programme is very important. But there is one point that must be stressed. There is an unfortunate habit that many vibration programmes have developed over the past 5-10 years; an undue focus on bearing fault detection above everything else. Detecting and correcting unbalance,