Predictive Maintenance (PDM)

Questions & Answers

What is Predictive Maintenance How is Vibration described?
(PDM)?
• Amplitude - (i.e., Normally Velocity)
• Maintenance actions based on machine
• Time (sec. or msec.)
Condition Data
• Frequency (Hertz or CPM)
• Vibration, Ultrasonic, and other relative
monitoring during normal operations
• Phase (degrees)
• Repairs when required with advanced notice
prior to unscheduled downtime
How are Vibrations measured?
How can PDM save money?
• Transducer - Converts Vibration -
Motion into electrical signal for
• Reduce repair costs – Early warning processing
• Reduce quantity of unnecessary inspections • Vibration Meter - Detects only amplitude
(i.e., No frequency components)
• Eliminate catastrophic failure costs
• Vibration Analyzer - Performs
• Reduce unscheduled downtime – Increase conversion of Amplitude vs. Time to
machinery Reliability Amplitude vs. Freq. (Spectrum Analysis)

Why use Vibration for PDM? What units are used to describe
Vibration?
• Adaptable to a variety of machines
• Displacement = Mils [Peak-to-Peak]
• Indicates Overall machine condition
(1 mil = 0.001")
• Indicates problem severity
• Velocity = In/Sec. [Peak]
• Analysis indicates specific faults
• Acceleration = g's [Peak]
(1 g = 32.2 ft/sec-sec)
What is Vibration?
Amplitude
• Motion of machine components

• Caused by dynamic forces

RMS = .707 Pk
What types of Vibration are there?
Peak-to-Peak Time
Time
Peak - to- Peak
Peak
• Periodic - (i.e., Machinery Shaft Speed)

• Random - (i.e., Varying)

• Transient - (i.e., Pump cavitation due to

improper system line-up)

© 2010 IMPACT Engineering, Inc. Page 1 of 4

 Predictive Maintenance (PDM)
Questions & Answers
Where are machinery Vibrations How are Vibrations analyzed?
measured?
• Spectrum Analysis (Amplitude vs. Freq.)
• Bearing Housings
• Parameter Trends (i.e. 1 x SS, 2 x SS,
HFD – High Freq. Bearing Wear Detector)
• Machine Casing
• Waveform & Phase Analysis
• Support Structure

Examples How can faults be detected early?

Typical Horizontal Machine • Full Signature (Spectrum) Analysis
V01
V02 V03 • Frequency Analysis Parameter Sets
(i.e., 1 x SS, 2 x SS, HFD) Used for detailed
trending
A01
A04
• Overall Vibration Levels (i.e., Meters) used
H04
H01 Driver
H02
H03
Pump
for initial trending. No specific machinery
faults can be identified with this method.

What types of faults can be detected?

Typical Vertical Machine
• Mis-alignment
A01
Fwd

RP1
Port Stbd
• Looseness

Aft • Bearing Defects / Wear

RP2
• Unbalance

RP3
A03
• Internal Component Rubbing

• Structural Resonant Conditions

RA4

Why is Ultrasonic (UT) analysis now

added to the PDM Process?
What are acceptable Vibration
Levels? • Enhances roller element bearing and
coupling fault detection
• ISO & Rathbone Charts
• Determines if correct amount of Lubricant is
• Machinery Comparison - History present in roller element bearings prior to
creating faults
• Manufacturer's Guidelines
• Used to detect outer race spinning condition
• Trending - Relative Levels in roller element bearing housings

© 2010 IMPACT Engineering, Inc. Page 2 of 4

 Predictive Maintenance (PDM)
Questions & Answers
How long has UT been used for Where do you measure Ultrasound?
bearing condition analysis?
With contact probe:
• Evaluation period ten (10) years • One measurement per bearing or on rigid
structure to bearing
• Simultaneous with Vibration Analysis
• Radial and/or Axial (load) direction
• IMPACT Programs’ acquire Over 80,000 UT
Measurements / Year. • Consistent locations

What are the frequency ranges of • Radial and/or Axial (load) direction
normal sound vs. ultrasound?
With non-contact microphone:
• Audible: 20 Hz – 10 kHertz • Listen to coupling with extension tube

• Ultrasonic: 20 kHertz – 200 kHertz How is bearing ultrasound severity

determined?
• Acoustic Emission: 200 kHz – 2 MHertz
• Good bearings and Couplings produce
Why has Ultrasound now an integral smooth / mono-tone sounds without
part of Condition Monitoring? distinct characteristics

• Simple and quick measurement • Under lubricated bearings produce clicking

sounds that indicate excessive friction
• Indicates high friction condition – so associated with a dry condition
bearings can be greased and saved!
• Bad / defective bearings produce distinctive
• Provides early warning of developing faults popping / excessive clicking sounds that
so that planned repairs can eliminate typically do not reduce / disappear with
catastrophic failures greasing

What are the details of UT test • Dry/worn/damaged Couplings produce

equipment? excessive popping / clicking

• In general, increases in dynamic loading or

• Ultrasound frequencies are shifted into speed increase digital amplitude values
audible range with detailed audible measured
characteristics
• 39 kHerz (fault detection proven by NASA
and others) What is the typical condition of
bearings analyzed with UT?
• 4 kHertz Bandwidth (Narrow Band)
• Bearing OK
• Fixed frequency and filter (no tuning) • High friction / Lack of lubricant – Grease!

• Developing fault – Greasing reduces UT and

• Short wavelength (source location)
popping sounds but return after time
• No special sensor mounting (hand held)
• Significant / severe fault present – Greasing
does not reduce UT levels nor does severe
• Precision Measurement (Digital Meter)
popping reduce

© 2010 IMPACT Engineering, Inc. Page 3 of 4

 Predictive Maintenance (PDM)
Questions & Answers
What are the advantages of the What Special Tests can be
Ultrasound Technology? conducted?

• Low cost with high benefits • Variable Speed / Load

• Less time to get results • Impact Testing

• Requires less skill and training than • Relative Motion Analysis

vibration equipment
• Driver un-coupled
• Locates specific bearing with fault
• Shaft alignment check
• Non-contact measurement for coupling
analysis in now available • Balance sensitivity

• Early warning to save bearing or couplings Machinery problems are caused by?
with lubrication, coupling maintenance, or
shaft alignment • Normal wear

How is Machinery Problem Severity • Poor installation - design

determined?
• Operational problems
• By Machine type • Improper maintenance procedures
• Fault type
What problem feedback info. is
• Fault severity useful?

• Spare machine availability • Operational actions taken

• Critical machine for operation • Details of faults found

• Past experience with the type of fault • Possible cause of the fault

• Maintenance required and time to make • Details of repair work done

repairs
• Actual repair costs
How Is Problem Severity Rated?
• Estimated costs if problem was undetected
and had failed catastrophically
• Severe

• Significant

• Developing

• None, continue to monitor

© 2010 IMPACT Engineering, Inc. Page 4 of 4