STD 124 Predictive Maintenance
STD 124 Predictive Maintenance
STD 124 Predictive Maintenance
Amended edition
FOR RESTRICTED
CIRCULATION
No.
PREDICTIVE MAINTENANCE
PRACTICES
1
OISD RP-124
First Edition, March, 1990
Amended edition, August, 1999
FOR RESTRICTED
CIRCULATION
No.
PREDICTIVE MAINTENANCE
PRACTICES
Prepared by
COMMITTEE ON
INSPECTION OF ROTARY EQUIPMENT
2
NOTE
3
FOREWARD
4
COMMITTEE ON
List of Members
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Name Designation & Status
Organisation
____________________________________________________________
__________________________________________________________________
In addition to the above, several other experts from industry contributed, in the
preparation, review and finalisation of this document.
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PREDICTIVE MAINTENANCE PRACTICES
CONTENTS
SECTION
1.0 Introduction
2.0 Scope
3.0 Vibration
3.1 Vibration parameters
3.2 Criteria for Measurement
3.3 Filter out and filter in
4.0 Vibration measurement and severity standards
4.1 Vibration measurement
4.2 Vibration recording
4.3 Vibration severity standards
5.0 Vibration analysis
5.1 Data acquisition
5.2 Data interpretation
6.0 Shock pulse measurement
6.1 General
6.2 Unit and pick-up points
6.3 Terminology
7.0 Frequency of vibration & shock pulse
measurement
7.1 Classification
7.2 Frequency of measurement
8.0 References
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PREDICTIVE MAINTENANCE PRACTICES
7
1.0 INTRODUCTION
The Rotary equipment plays a vital
role in hydrocarbon processing industry.
2.0 SCOPE
1
frequencies, i.e. the machinery does not
The displacement, velocity and vibrate at a single frequency but vibrate at
acceleration of vibration are referred to as many frequencies. (The frequency is
the Amplitude of vibration. Displacement, decided by the troubles causing vibration).
velocity and acceleration of vibration are
directly related. Vibration velocity is directly The total amplitude of vibration
proportional to the displacement and the measured is the vector sum of vibrations at
frequency as shown in Equation 1 and different frequencies. This is termed as the
Vibration acceleration is directly proportional ‘Filter out' amplitude.
to the displacement and frequency squared
as shown in Equation 2. When the vibration is complex, we
will have to analyse the vibration to know the
V Peak =52.30D (F/1000) x 10 -3 ....(1) amplitude at different frequencies of interest.
g peak =5.6 D (F/1000) 2 x 10 - 4 ....(2) For this purpose, vibration analysers are
V peak = Vibration velocity in mm/s peak made use of. With this, by tuning the filter,
g peak = Vibration analysis peak vibration amplitude at different frequencies
D= “Peak to peak" displacement in can be measured. This is termed as ‘Filter
microns in' amplitude.
F = Frequency in CPM
4.0 VIBRATION MEASUREMENT AND
The forces, which cause vibration, SEVERITY STANDARDS
are generated through the rotating motion of
the machine parts and these forces change 4.1 VIBRATION MEASUREMENT
in amount and direction and the rotating part
changes its position with respect to rest of Electronic instruments for measuring
the machine. Hence the frequency of the machinery vibration are generally classified
vibration produced would be related to the as meters, monitors and analysers.
rotating speed of the part which has the
trouble. Because of this, it is essential to a) A vibration meter is a portable device
know the vibration frequency for analysis. and used for periodic vibration checks
on machinery to determine the overall
Vibration severity is a function of both the machine vibration level.
distance the vibrating part moves from its b) A vibration monitor is similar in function
position of rest (peak displacement) and the to a vibration meter, but is permanently
number of times the vibrating part moves installed to provide continuous
about its position of rest in unit time monitoring of equipment vibrations.Note 1
(frequency). Since vibration velocity is a c) A vibration analyser includes a tunable
function of the displacement and frequency, filter for separating the individual
unfiltered vibration velocity should be frequencies of complex vibration. This
recognised as a direct measure of vibration can measure and record all vibration
severity. amplitudes at different frequencies.
2
5.0 VIBRATION ANALYSIS c) Since many machine troubles have
similar characteristics and several
The purpose of vibration analysis is troubles may be present in a machine
to identify the specific machinery problem. simultaneously, it becomes necessary to
For this purpose, the initial reading taken choose between several possibilities.
during the commissioning of the equipment
should be taken as the most ideal base line The vibration and noise identification
data". After that, whenever overall chart given in Table 1.6 gives a
machinery vibration has revealed a comprehensive listing of most of the
significant increase in “base line data", common problems encountered and provide
vibration analysis should be carried out to a relative probability rating number which
pin-point the machinery problem. The provides an indication of which trouble is the
vibration analysis procedure is divided into most likely set of circumstances. If the
two steps: analysis does not give an indication of the
problem, signature analysis should be
a) Data acquisition carried out.
b) Data interpretation
6.0 SHOCK PULSE MEASUREMENT
5.1 DATA ACQUISITION (SPM)
6.1 GENERAL
Vibration data can be obtained for
analysis by applying the techniques given Shock pulse measurement is based
below: on monitoring the mechanical impacts
caused by bearing damage and operating
a) Amplitude vs frequency condition problems.
b) Amplitude vs time
c) Amplitude vs frequency vs time 6.2 UNIT AND PICK-UP POINTS
d) Time wave form
e) Orbits The sensitivity of the SPM method is
f) Amplitude vs phase vs rpm such that the shock pulses generated by a
g) Phase analysis typical antifriction bearing increase upto
h) Mode shape interpretation. 1000 times from when the bearing is in good
condition to the condition when the same is
5.2 DATA INTERPRETATION about to fail. For covering this large range,
a logarithmic scale is used and the shock
Once the data mentioned in 5.1 are pulse values are expressed in decibels (db).
obtained, the next step is to interpret the
data thus obtained for identifying the Shock pulses are generated mainly
machinery problem. This is done by in the load zone of the bearing and spread
comparing the reading with the characteristic spherically from the point of impact through
vibration due to typical machinery troubles. the bearing, its housing and adjacent
machine parts. The shock pulses are
a) The chart given in Table 1.4 lists the dempened when they pass an interface or
vibration frequencies normally are forced from their straight path.
encountered in terms of rpm and the
possible cause of vibration. Referring to 6.3 TERMINOLOGY
the chart, we can identify the part
causing trouble. Following are the terminology
associated with shock pulse measurement.
b) The vibration identification chart given in i) Initial Shock Value (dbl)
Table 1.5 lists most common cause of Even a newly installed and properly
vibration together with its relation to the lubricated bearing generates shock pulses.
amplitude, frequency and position of
phase reference mark under strobe light.
3
4
5
6
7
This is known as Initial Shock Value (dbl).
This value is primarily dependent on the
rotating speed and the bore dia as shown in
Table 1.7
v) Maximum Value
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TABLE 1.4
VIBRATION FREQUENCIES AND LIKELY CAUSES
Frequency Most Likely Other Possible Causes and
in terms causes Remarks
of RPM
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1xRPM Unbalance 1. Eccentric Journals, Gear or Pulleys
2. Misalignment or Bent shaft if high axial
vibration 3. Bad belts if RPM of belt
4. Resonance
5. Reciprocating
forces 6 Electrical problems
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2 x RPM Mechanical 1. Misalignment-if high axial vibration
looseness 2. Reciprocating forces
3. Resonance
4. Bad belts if 2x RPM of belts
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3 x RPM Misalignment Usually a combination of misalignment and excessive
axial clearances (looseness)
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Less than Oil Whirl 1. Bad drive belts
1 X RPM (less than 2. Background vibration
half RPM) 3. Sub-harmonic resonance
4. "Beat" vibration
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Synchronous Electrical Common electrical problems include rotor bars,
(A.C. line problems eccentric rotor, unbalanced phases in poly-phase
frequency) systems, unequal air gap
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vi) Instrument and Evaluation Chart i) An introduction to Machinery Analysis and
Monitoring
The basic measuring equipment ii) BS 4675 : Part I : 1976 (ISO2372) -
consists of the shock pulse transducer with Mechanical Vibration in rotating and
the probe which picks up the shock pulses reciprocating machinery
and the shock pulse meter which measures iii) API 610 : Centrifugal pump for general
the magnitude. Once the readings are taken refinery service
and tabulated as shown in Table 1.8., the iv) API 611 : General purpose steam turbine for
intensity can be checked from the shock refinery service
pulse diagram given in Figure 2.0 v) API 612 : Special purpose steam turbines for
refinery service
7.0 FREQUENCY OF VIBRATION AND vi) API 617 : Centrifugal compressor for general
SHOCK PULSE MEASUREMENT refinery service
7.1 CLASSIFICATION vii) Condition monitoring of roller bearings with
shock pulse meter
The entire equipment in oil industry viii) IRD Mechanalysis Advanced Training Manual
should be classified into three categories: ix) Predictive maintenance Manual of Indian Oil
Corporation
i) Critical x) Sawyer’s turbomachinery Handbook
ii) Semi-critical xi) Instruction Manual of Hard bearing balancing
iii) Non-critical machine
xii) Turbomachinery Handbook published by
The equipment that can cause unit Hydrocarbon Processing
shutdown and the failure of which will lead to
release of hydrocarbons should be classified
as Critical equipment. Mostly these
equipment will not be having any spare
equipment. The equipment that can cause
only production loss should be classified as
Semi-critical equipment. Rest of the
equipment should be classified as Non-
critical.
7.2 FREQUENCY OF MEASUREMENT
dbm Frequency
0-20 1-3 months
20-35 1-2 months
35-65 Daily
8.0 REFERENCES
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