적용사례-무선진동_온도 상태모니터링시스템(Wi-care): Fan의 볼베어링

적용사례-무선진동_온도 상태모니터링시스템(Wi-care): Fan의 볼베어링

Wi-care wireless vibration and temperature condition monitoring system

Ball Bearing defect detection on a fan in chemical industry  화학공장의 팬에서 볼베어링 결함검출

Introduction

A few of the rotating machines in your plant have the criticality to bring production to a halt. 여러분의 사이트에서 가동하고 있는 몇몇 회전기계들은 생산중단에 이를 만큼 중요한 역할을 맡고 있을 것이다. On top of a shutdown system installed on this equipment to prevent catastrophic failure, it is interesting to think about having continuous health information about these machines. Roughly 50% of machinery damages, leading to downtime, are linked to process, and 90% of them are predictable – even manageable. 시스템의 돌발정지는 재앙에 가까운 수준의 피해를 유발할 수도 있으므로 이러한 기계에 대한 지속적인 건강상태에 대한 정보는 매우 중요하다. 대략 기계손해의 50%정도는 공정의 정지로 이어지며 그 중의 90%는 예측할 수 있었다는 것은 생각해 볼 만한 사항인 것이다. The wireless vibration added values are well known and justify fully the use of Wi-care regardless of whether you want to revamp your actual wired system or install a completely new one. Wicare의 사용으로 인한 무선진동모니터링의 가치는 기존의 유선방식 시스템을 개선하는 것과 상관없이 중요한데 이 것은 다음의 사례처럼 마찰이나 윤활의 지속적인 모니터링에 사용되는 원격분석시스템으로 완성화 된다.  The following case study describes and explains a typical remote analysis application of continuous friction/lubrication monitoring on a mixer in chemical plant. The continuous surveillance was set up in a very effective way for the customer and analyst:  

 

For the Customer: Easy detection, fast diagnosis and monitoring from the friction issue on a critical mixer asset with low upfront investment and lower costs than manual/traditional online monitoring. 

사용자에게는 전통적인 온라인모니터링시스템보다 작은 투자로 위급한 순간을 감지하기 쉬운 시스템으로,,,

For the analyst: Continuous data, instant trend data and 24/7 protection, higher confidence without any travel or measurement time spent  

분석전문가를 위해서는 매번 사이트에 방문하지 않고 원격 진단을 이용할 수 있는 방법의 시스템으로 소개한다.

The world is turning wireless, condition monitoring too!

세계는 무선방식으로 빠르게 변하고 있고 상태감시시스템도 이에 예외가 아니다.

 

Equipment, plant overview,

The chemical plant produces ultra-fine thermoplastic powder for the automotive, coating, and cosmetics industry. 자동차, 코팅, 화장품용 초정밀 합성섬유분말을 생산하는 서유럽위치 화학회사에 적용The production is located in Western Europe; the plant is of medium size and operates 24 Hours ,7 days a week. The Equipment in question is an Industry standard extraction fan in the powder production section. One electrical drive, a belt coupling drive, and two bearing fan shaft coupled to an overhung fan. 하나의 모터와 벨트로 연결된 커플링이 두개의 베어링으로 지지되어 있는 팬을 구동한다. Bearing defects were detected with Wi-care wireless monitoring system. 베어링의 결함이 각 베어링에 설치된 wicare 무선 모니터링시스템에 의해 검출되었다. This was confirmed by a portable data collector and the bearing problem was continuously trended with Wi-care. until a planned shutdown

Analyst diagnosis and spectrum justification: Ball bearing frequency and friction. 현장에서는 정밀분석기로 이를 측정하여 결함(스펙트럼분석과 베어링주파수 및 마찰주파수의 확인)을 확정하였고 생산을 일정한 동안 지속하고 있는 동안에 계속 설비의 결함을 모니터링하고 있었다. The Wi-care system is set up with one sensor on the electrical drive, and two sensors on the fan shaft. Outlined below is the standard spectrum collected with the Wi-care wireless monitoring system at the fan bearing coupling side. Display is in acceleration units G PK. The four dominant peaks from the right side of the screen show the bearing fault frequency and its harmonics. Seen below is a spectrum and wave form measurement performed with portable data collector on the same exact point,bearing on the fan,coupling side. 네개의 주요주파수 피크는 베어링결함주파수와 하모닉을 나타내고 있다.

Analyst observations 분석자 관찰사항

Same predominant bearing fault on the Wi-care and portable data collector measurement in April 2014.   We detected an obvious spectral peaks and noise due to friction on the fan bearing non coupling side. This revealed a typical lubrication defect. 명백한 스펙트럼 피크와 노이즈를 볼 수 있었고 이 것은 전형적인 윤활의 문제이다. The fault is important and justify an action. We can also see a fault frequency on the fan bearing coupling side at 5.251 order. The amplitude gives grounds for concern but does not justify change out of the bearing at this time. We recommend that the Auto-Lubricator be checked to ensure it is performing correctly. In addition We will monitor the bearing fault frequency and friction trend with Wi-care in order to control lubrication and follow bearing fault degradation.  Following the diagnosis and remedial action, Wi-care provided a clear trending of data to the operators and predictive team.

키워드	Wi care, I care, 방폭무선센서, 무선진동센서, 스펙트럼 무선전송, 인터넷기반, 설비진단, 진동문제, 원격진단

 

All copyright  한국CBM(주)  written by BISOPE , vs72@naver.com, 070-4388-0415,  www.kCBM.kr 

 

적용사례-무선진동_온도 상태모니터링시스템(Wi-care): 크러셔 유성기어

적용사례-무선진동_온도 상태모니터링시스템(Wi-care): 크러셔 유성기어

Wi-care wireless vibration and temperature condition monitoring system

Friction and lubrication under control: Mixer in a chemical plant 

화학공장에설치된 Mixer설비의 마찰과 윤활문제

Introduction

A few of the rotating machines in your plant have the criticality to bring production to a halt. On top of a shutdown system installed on this equipment to prevent catastrophic failure, it is interesting to think about having continuous health information about these machines. Roughly 50% of machinery damages, leading to downtime, are linked to process, and 90% of them are predictable – even manageable. The wireless vibration added values are well known and justify fully the use of Wi-care regardless of whether you want to revamp your actual wired system or install a completely new one.   The following case study describes and explains a typical remote analysis application of continuous friction/lubrication monitoring on a mixer in chemical plant. The continuous surveillance was set up in a very effective way for the customer and analyst:   For the Customer: Easy detection, fast diagnosis and monitoring from the friction issue on a critical mixer asset with low upfront investment and lower costs than manual/traditional online monitoring.  For the analyst: Continuous data, instant trend data and 24/7 protection, higher confidence without any travel or measurement time spent   The world is turning wireless, condition monitoring too!   Equipment, plant overview, Context The Chemical site is a Phosphoric Acid Plant operating 24 Hours 7 d

 

Equipment, plant overview,

Context The Chemical site is a Phosphoric Acid Plant operating 24 Hours 7 days a week, established for many years in Africa. 일년내내 상시가동되는 아프리카 화학공장. The Equipment in question is a large mixer involved in the acid production and a very large fan for production air treatment. 산성화학물에 관련물질을 생산하는 대형혼합기에 공기를 주입하는 대형 팬설비. Routine measurement performed with potable data collector indicated friction on both of these machines bearings. 포터블 진동데이타 수집장치로 정기적으로 측정하여 베어링에 마찰을 감시한다.  Cage frequency issues were detected, indicating higher than normal levels of friction. 케이지 주파수가 감지되었고 마찰관련 진동이 비정상적으로 증가하였다. These raised levels would not warrant an immediate replacement but the next planned shutdown was in 10 months time.  진동이 상승되었지만 당장 교체할 수 없었고 일정상 10개월이후에나 셧다운이 가능하였다. I-Care suggest the installation of Wi-care wireless vibration/temperature monitoring system and the analysis/trending by its remote team to ensure no premature escalation  in the evolution of the defect. 우리는 무선진동/온도 모니터링시스템을 이용하여 원격으로 결함을 감시하였다.

The Wi-care system is set up on the main bearing housing of the mixer shaft. Outlined below is the standard spectrum collected with the Wi-care wireless monitoring system at the lower radial position. Display is in acceleration units G PK. The dominant frequency appears at 185 Hz and its harmonics. In addition there is a lot of random vibration/noise visible in the spectrum indicating friction   Analyst diagnosis and spectrum justification: Friction in mixer bearings

Analyst observations

 Same predominant frequency from October 2013 around 180 Hz (variable machine speed).   The friction is easy to identify with the portable data collector and the Wi-care wireless even though the levels are not high. 마찰관련 데이터는 포터블 데이터수집기와 wicare무선진동센서를 이용해서 진동량이 높지 않아도 쉽게 확인할 수 있었다. The close attention to bearing lubrication levles based on Wi-care monitoring maintains a stable friction and avoidance of a decrease in bearing health. wicare를 활용하여 모니터링하는 방법으로 베어링 윤활 수준에 집중하였고 안정적인 마찰상태를 유지할 수 있었고 베어링의 상태를 일정하게 유지할 수 있었다.

키워드	Wi care, I care, 방폭무선센서, 무선진동센서, 스펙트럼 무선전송, 인터넷기반, 설비진단, 진동문제, 원격진단

 

All copyright  한국CBM(주)  written by BISOPE , vs72@naver.com, 070-4388-0415,  www.kCBM.kr 

적용사례2-무선진동_온도 상태모니터링시스템(Wi-care): 크러셔 유성기어

적용사례2-무선진동_온도 상태모니터링시스템(Wi-care): 크러셔 유성기어

Wi-care wireless vibration and temperature condition monitoring system

Friction and lubrication under control: fan in a chemical plant  화학공장에설치된 팬설비의 마찰과 윤활문제

Introduction

Vibration analysis online is the natural evolution of vibration analysis. Vibration analysis was first applied by the use of portable data collectors and data recording gathered from the route. Depending on the condition monitoring program, the manual data was collected periodically from 2 weeks to 6 months. With technology changes, the need to monitor machine status more closely and even to get data continuously is increasingly common. Online vibration monitoring systems were developed for this need. Their performance is at least equivalent or superior to portable systems. However their main advantage is the ability to access data at any time. Wireless vibration monitoring removes some of the major drawbacks of previous systems such as time and installation costs associated with a wired system. A wireless online condition monitoring system offers the possibility to extend your predictive maintenance strategy to the complete plant where wired systems typically protect production assets.   The following case study describes and explains a typical remote analysis application of continuous friction/lubrication monitoring on a fan assembly. The continuous surveillance was set up in a very effective way for the customer and analyst :   For the Customer: Easy detection, fast diagnosis and monitoring from the friction issue on a critical fan with low upfront investment and lower costs than manual/traditional online monitoring.  For the analyst: Continuous data, instant trend data and 24/7 protection, higher confidence without any travel or measurement time spent   The world is turning wireless, condition monitoring too!   Equipment, plant overview, Context

The Chemical site is a Phosphoric Acid Plant operating 24 Hours 7 days a week, established for many years in Africa. The Equipment in question is a large mixer involved in the acid production and a very large fan for production air treatment. Routine measurement performed with potable data collector indicated friction on both of these machines bearings. Cage frequency issues were detected, indicating higher than normal levels of friction. These raised levels would not warrant an immediate replacement but the next planned shutdown was in 10 months time. I-Care suggest the installation of Wi-care wireless vibration/temperature monitoring system and the analysis/trending by its remote team to ensure no premature escalation  in the evolution of the defect.

The Wi-care system is set up with two sensors, one on the bearing supporting the coupling disc and one on the fan bearing wheel side.  시스템은 두개의 센서로 구성되어 있으며 하나는 커플링측 베어링 지지대에 나머지 하나는 팬 베어링 반부하측에 설치하였다. Displayed below is the standard spectrum collected with the Wi-care wireless monitoring system on vertical direction on fan bearing. Display in acceleration unit G PK.  The spectrum shows a random noise vibration indicating friction inside the bearing. Some peaks (including the dominant one at 375 Hz) are related to ball frequency. 스펙트럼은 랜덤 노이즈 진동현상을 나타내고 있으며 이 것은 베어링 내부에서 발생하는 마찰을 의미하고 있다. 375Hz를 포함한 주요 피크 주파수는 베어링 볼 주파수와 관련이 있다. The level of friction is low (3 times lower than 6 months before). 진동의 레벨은 6개월전 보다 3배정도 더 낮게 나타났다.

키워드	Wi care, I care, 방폭무선센서, 무선진동센서, 스펙트럼 무선전송, 인터넷기반, 설비진단, 진동문제, 원격진단

 

TEL: 02-6475-8178   FAX: 02-6971-8178   mail: sales@astint.co.kr

Copyright, 에이에스티(AST) , www.ASTint.co.kr  

 

적용사례-무선진동_온도 상태모니터링시스템(Wi-care): 크러셔 유성기어

적용사례-무선진동_온도 상태모니터링시스템(Wi-care):

​크러셔 유성기어

무선진동 온도 상태모니터링시스템을 통해 시멘트 크러셔 유성기어박스의 돌발사고를 미연에 방지했던 사례 Wi-care wireless vibration and temperature condition monitoring system.

Prevention of a catastrophic failure on a cement crusher planetary gearbox Introduction

완벽한 솔루션이란 완벽한 감시를 하여 완벽한 진단을 할 수 있는 전문가가 주위에 있는 경우이다. In a perfect world, the easiest solution to ensure maximum production uptime, would be for all industry experts to live onsite around the clock! With the aim of ensuring that dedicated experts are always in the neighborhood, I-care created its condition monitoring remote diagnosis solution. The Wi-care wireless condition monitoring system performs online, real-time analysis of a particular machine to predict eventual failure. 이 시스템은 상시 감시 모니터링이 가능한 전문가에 의해 진단한 결과 The system performs the onsite data collection while certified analysts analyse your data offsite to deliver comprehensive recommendations 24/7. This wireless and remote strategy offers cost savings over routine-based maintenance and a very flexible solution for troubleshooting and monitoring.   The following case study represents a typical remote analysis application of a gear defect. The fault was detected in a very effective way for the customer and analyst :   For the Customer: Continuous surveillance of its critical asset with low upfront investment and lower cost than manual/classic online monitoring  분석가는 측정시간에 낭비할 필요없이 지속적인 데이터 축적이 필요하다.For the analyst, Continuous data (Historic and Remedial Action Recommendation) from the monitoring Center without any travel or measurement time spent   최근 전세계적으로 무선시스템의 유행이 번지고 있으며 상태모니터링도 예외가 아니다.The world is turning wireless, condition monitoring too!   Equipment, plant overview, Context The Manufacturing site is a Cement Plant operating at close to full capacity, established for many years in Western Europe. 대형 시멘트 볼밀기계구성요소로 기어박스가 설치된 설비The Equipment is a very large cement ball mill. The suspected machine components are the gearbox and its associated electrical drive (1MW). 고객은 진동이 증가하여 의뢰하였고 무선 스펙트럼 전송 센서인 Wi-care를 설치하였고 무선으로 원격에서 진동의 증가 원인을 분석하였다.The Customer requested I-Care support after a suspected increase in vibration level. In order to do an in-depth and concise monitoring and diagnosis of the vibration on the complete assembly, the analyst decided to install Wi-care wireless system.
분석가의 진단과 스펙트럼은 기어주파수가 진동의 원인이라는 것을 확인하였다. Analyst diagnosis and spectrum justification: Gear frequency, The Wi-care system is set up on the gearbox and the electrical drive in minutes using magnetic locators to cover classical vibration directions, vertical, horizontal and axial planes. Note on the right side of the picture the Wi-care speed sensor directly measuring with a key-phasor on the shaft.  Standard spectrum collected via Wi-care in the vertical axis. Display in speed units. 주요주파수는 373Hz로 그 하모닉이 존재하며 5Hz의 사이드밴드가 존재한다. 진폭은 4 mm/sec RMS .The dominant frequency appear at 373,9 Hz and its harmonics. On a closer zoom on 373,9 Hz appears modulation at 5Hz. The amplitude is close to 4 mm/sec RMS.

Following on from inspection of the drawings and data sheets, we can find the gearbox specifications and calculate theoretical fault frequencies

분석한 결과 GMF(기어의 맞물림주파수)로 확인되었고 5Hz는 링기어의 회전결함으로 파악되었다. Calculated Gear mesh frequency of 373,71 Hz and its harmonics match the measured frequency of 373,9 Hz. Detected 5Hz modulation are linked to a ring defect (5.01 calculated). 진폭 trend는 몇일 사이에 두배로 성장하였고 Amplitude trend indicate a 100% growth in a few days. The decision was taken by the customer based on analyst recommendations via Wi-care measurement to initiate the maintenance inspection. 근본원인은 조립불량에 이은 과도한 기계적이완(looseness)로 인한 구조의 크랙발생인 것으로 판단되었다. The Root cause of the gear defect is an excessive looseness in the gear assembly due to structural cracks.

Wi care를 이용한 설비진단의 결과, 투자대비 회수율 ROI

 

키워드	Wi care, I care, 방폭무선센서, 무선진동센서, 스펙트럼 무선전송, 인터넷기반, 설비진단, 진동문제, 원격진단

 

TEL: 02-6475-8178   FAX: 02-6971-8178   mail: sales@astint.co.kr

Copyright, 에이에스티(AST) , www.ASTint.co.kr