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TX5600 Handbook - Vibration TX5600-HV-EN-01 3 TX5600 Vibration Contents Introduction 4 1. The Nature of Vibration 5 1.1 Vibration Frequency 6 1.2 Vibration Amplitude 7 1.3 Vibration Phase 9 1.4 Vibration Spectrum 10 1.5 Vibration Parameter Conversion 10 2. Using Vibration to Evaluate Machine Condition 12 2.1 When to use Displacement, Velocity or Acceleration 12 2.2 Classification of Vibration Severity 14 2.3 Monitoring Acceleration 15 2.4 Monitoring Velocity 15 3. Methods of Vibration Monitoring 16 3.1 Piezo-electric Accelerometers 16 3.2 Piezo-resistive Accelerometers 17 3.3 Eddy Current Probes 17 3.4 Contact Displacement Sensor 18 3.5 Industrial Applications 18 4. Determining the Right Method 23 4.1 Sensitivity Range of ac Output Accelerometers 23 4.2 Sensitivity Range of dc Vibration Sensors 23 4.3 Frequency Range 24 4.4 Temperature Range 24 4.5 Mounting the Sensor 25 4.6 Where to Mount the Sensor 29 4.7 Connecting the Sensor 31 4.8 Monitoring Equipment 33 5. Typical Vibration Monitoring Applications 40 5.1 Underground Booster Fan Monitoring Utilising a Programmable Sensor Controller and the TX5633 Vibration Sensor 40 5.2 Pump Monitoring 42 5.3 Vibration Monitoring in Hazardous Areas 45 5.4 Screening and Bunker Outfeed Monitoring 46 5.5 Conveyor Drive Monitoring 47 6. Interpreting Vibration Data 49 6.1 Imbalance 51 6.2 Gearmesh Problems 51 6.3 Bearing Breakdown 52 Disclaimers 53 Trademarks 53 Contact Details 53 Document History 53 www.trolex.com 4 TX5600-HV-EN-01 Introduction All machines and moving mechanical devices generate a wide spectrum of vibration in normal use. The frequency and magnitude of vibration generated by each component part of a machine varies greatly, and the characteristics of each vibration signature changes further as a machine ages and deteriorates, resulting in additional mechanical stresses. The changes in vibration characteristics can be measured and monitored to provide a very powerful machine condition monitoring tool. What at first appears to be a rather mundane subject, turns out to be a valuable technique for detailed diagnostic machine health monitoring that can independently evaluate the current state of the different parts of a machine and even predict the probability of an approaching system failure, so enabling corrective action to be taken before its too late. Because of the wide and variable nature of vibration there is no standard solution to the best method of condition monitoring. The aim of this handbook is to set out a basic understanding about the cause and effects of vibration, and how to use this information to determine the best methods of monitoring for a particular application. Advise and guidance is also given about the various analytical methods that can be exploited for optimal performance of a monitoring system. Several typical application examples also serve to illustrate the possibilities. www.trolex.com TX5600 Handbook - Vibration TX5600-HV-EN-01 5 1. The Nature of Vibration Vibration in a structure is a result of its response to an internal or externally generated stimulus, causing a repeated mechanical movement. It is generally assumed that it is vibration itself that causes damage to machines and structures, but this is not the whole story. Vibration induces stress into the materials of the structure and this ultimately leads to mechanical fatigue and breakdown. The degree of vibration amplitude present is dependant upon both the level of dynamic forces applied and the dynamic resistance of a system. A rigidly mounted machine will experience lower amplitude levels and much of the vibration will be transmitted through the floor into surrounding structures. If a machine is installed on resilient mountings the magnitude or amplitude of vibration will probably increase due to the reduction in dynamic resistance permitted by the flexible mounting, but this will not result in any additional fatigue damage as the same forces are being dissipated within the machine. Several important components of vibration are: 1. Frequency – How many times does the machine or structure vibrate per minute or per second? 2. Amplitude – The degree or magnitude of vibration in microns, mm/sec or g 3. Phase – How is the member moving in relation to a reference point? 4. Spectrum – Vibration presented as a frequency spectrum 5. RMS and Peak – Vibration parameters conversion www.trolex.com 6 TX5600-HV-EN-01 1.1 Vibration Frequency Frequency can be calculated from a displacement waveform, by measuring the time period (T) of one cycle and converting this to determine the frequency Hz. This is an example of a time waveform which plots vibration amplitude against time. Checkpoint As the waveform is a truly sinusoidal direct comparisons can be made between its peak-to-peak and RMS amplitudes, see Section 1.5. Time waveforms are an excellent analytical tool to use when analysing gearboxes. The sensor can be attached close to the input or the output shaft bearing and is capable of revealing broken or chipped gear teeth on each revolution of the shaft or gearwheel. The illustration above shows a time waveform, showing the repeated impact of a broken tooth. www.trolex.com TX5600 Handbook - Vibration TX5600-HV-EN-01 7 The same data can be presented on a frequency baseline to analyse the fault at the rotational speed of the shaft or gearwheel. The illustration above is of a frequency waveform, showing the impact at the rotational speed. Imbalance, misalignment, bent shaft, eccentric rotor, and other problems will often produce a similar response in the frequency domain. Time waveforms are particularly useful for low-speed shafts and gears, or mechanical components that oscillate backwards and forwards. They are often the only analytical tool which can be effectively used at lower rotational speeds or cycle times. 1.2 Vibration Amplitude Vibration amplitude is a measure of magnitude of vibration and can be expressed in terms of displacement, velocity or acceleration. 1.2.1 Displacement Displacement is a measure of the total travel of a measurement point, between the two extremities of vibration and is usually expressed as a distance in microns. When a machine is being subjected to excessive dynamic stress at very low frequencies, displacement may be a good indicator of vibration severity since the machine or structure, may be flexing too much, being subjected to impacts, or simply being flexed too far. 1.2.2 Velocity The velocity of vibration is a measure of the speed at which a mass is moving or vibrating during its oscillations, the faster a machine flexes, the sooner it will fail in fatigue. Vibration velocity is directly related to stress fatigue. www.trolex.com 8 TX5600-HV-EN-01 When an oscillating mass is suspended from a spring the velocity of the mass reaches its maximum value, or peak, at the mid point, the point at which the mass is fully accelerated (acceleration is zero). It now begins to decelerate in the second half of the cycle. Velocity is expressed as millimetres per second (mm/sec). Checkpoint In reality, vibration response is not usually a pure sine wave and an analyser is invariably used to capture peak velocity. www.trolex.com TX5600 Handbook - Vibration TX5600-HV-EN-01 9 1.2.3 Vibration Acceleration When a component on a machine vibrates, it experiences acceleration since it continually changes speed as it oscillates from one peak to the other. Acceleration is greatest at the instant when velocity is at its minimum, at the point where the mass has decelerated to a stop and is about to begin accelerating again in the opposite direction. Acceleration is the rate of change in velocity and is normally expressed in units of g, where 1 g = 9.81ms–2. The greater the rate of change of velocity, the greater will be the forcesand stresses on the machine due to the higher acceleration. At high frequencies, the excessive force can reach a point where the bearing lubrication can break down allowing the metal surfaces of bearings to come into contact, potentially causing catastrophic failures. These forces are directly proportional to acceleration (force = mass x acceleration) and acceleration mode is the parameter most often employed for machine protection. 1.3 Vibration Phase Phase is a relative expression of how one part of the machine is moving or vibrating with respect to another part, or to a fixed reference point on the same machine. Phase is mostly used as an in depth analytical tool, when initially setting up a machine, to ensure it has been mounted and aligned correctly. It is rarely used for continuous monitoring of machine condition. www.trolex.com 10 TX5600-HV-EN-01 1.4 Vibration Spectrum This frequency domain presentation of a time waveform is called a spectrum analysis and is sometimes referred to as a vibration signature. 1.5 Vibration Parameter Conversion It is possible to convert from one amplitude parameter to another, using either electronic conversion or a mathematical formula. Electronics or processing software, can also convert between RMS (root mean square), peak and peak-to-peak. The illustration below shows the relationship between RMS, peak and peak-to-peak, for a purely sinusoidal waveform. Peak-to-peak x Peak x RMS x Average x Peak-to-peak = 1 2 2.828 3.142 Peak = 0.5 1 1.414 1.571 RMS = 0.354 0.707 1 1.5 Average = 0.318 0.636 0.9 1 eg. peak-to-peak x 0.5 = peak www.trolex.com TX5600 Handbook - Vibration TX5600-HV-EN-01 11 Most vibration waveforms are not sinusoidal in practice and peak and peak-to-peak readings become less useful and RMS assessment is most often used. RMS amplitude gives a more accurate representation of the energy within the vibration, and hence the force that will be exerted. www.trolex.com 12 TX5600-HV-EN-01 2. Using Vibration to Evaluate Machine Condition The causes of vibration in rotating machinery are numerous. Some may simply originate from machine set-up problems: • Imbalance of system • Misalignment of shafts • Bent or distorted shafts • Loose mechanical components • Ineffective or inadequate mounting structures Operational dynamic problems can also be identified: • Bearing deterioration • Mechanical components becoming loose or detached • Build up of debris on fan blades and other rotating parts • Chipped fan blades and rotors • Geartooth wear and breakage • Loss of lubrication If these problems are left unattended, catastrophic consequences can result. These can vary from machine downtime, lost whilst a seized bearing is replaced, or the complete disintegration of a fan when the out of balance causes the impeller blades to impact on the casing. By utilising vibration monitoring, an early warning of impending mechanical failure can be obtained. Further analysis of the vibration by a skilled engineer using frequency analysis enables the problem to be pinpointed and preventative maintenance can be implemented at a convenient time. 2.1 When to use Displacement, Velocity or Acceleration Movement displacement is an obvious indicator of how much a machine is vibrating, but the actual severity of vibration is also a feature of the frequency of vibration. The higher the frequency, the greater will be the energy expended for a given level of displacement. The vibration velocity of a measurement point increases as the displacement and or velocity increases. Conversely, if a machine is turning or oscillating slowly with the same amount of displacement, then the vibration severity will be proportionally lower. www.trolex.com TX5600 Handbook - Vibration TX5600-HV-EN-01 13 This can be demonstrated by a series of vibration severity characteristics generally applicable for a horizontal rotating machine. Vibration severity categories expressed in terms of velocity, are defined for various combinations of displacement and frequency. www.trolex.com 14 TX5600-HV-EN-01 2.2 Classification of Vibration Severity The standard general vibration severity chart is used to assess machine condition. However this is intended to be used as a guide and not an absolute reference. The standard of installation of the equipment and the general maintenance of it will have a significant effect on the vibration levels seen. Although the chart can be used as a general indication, trending of the vibration levels against time will give a more accurate indication of the change in condition of the machine. On fixed monitoring equipment, warning and alarm levels can be set to be within the Good condition zone. • Class I: Individual parts of engines and machines, integrally connected with the complete machine • Class II: Medium or large machines, typically electrical motors with 15 to 75 KW output • Class III: Large prime movers and other large machines with rotating masses mounted on rigid and heavy foundations up to about 300KW output • Class IV: Large prime movers and other large machines or turbines with rotating masses mounted on foundations which are relatively soft www.trolex.com TX5600 Handbook - Vibration TX5600-HV-EN-01 15 2.3 Monitoring Acceleration Measurement of acceleration is most widely employed when the vibration frequency of a machine is in excess of 1 kHz. Acceleration must be assessed in conjunction with vibration frequency to analyse the severity of vibration. High levels of acceleration combined with higher frequency is indicative of high vibration energy being dissipated and the various combinations can be classified. 2.4 Monitoring Velocity Vibration velocity monitoring is relatively independent of vibration frequency at lower levels of vibration. Consequently this method is generally adopted for monitoring the condition of slowly rotating or oscillating machines in the 10 Hz to 1 kHz range. www.trolex.com 16 TX5600-HV-EN-01 3. Methods of Vibration Monitoring A sensing element, mounted directly on to the machine, generates an output signal that is proportional to the amplitude and frequency present in the machine. The output signal format will be dependent upon the type of sensor being used. 3.1 Piezo-electric Accelerometers The piezo-electric accelerometer is widely used for industrial vibration measurement. Its construction consists of a crystal of piezo-electric material to which is attached a seismic mass. When the crystal is stressed in tension or compression during vibration, it generates an electrical charge which is proportional to the acceleration level it is experiencing. Internal circuitry converts this signal into a voltage or current for transmission to data collectors or process control loops. This robust device has no moving parts and offers long term stability and reliability. It has very wide frequency and dynamic ranges and the output signals can be electronically integrated to give velocity and displacement values. Accelerometers tend to be a more economical solution than the alternative devices and are available for a wider range of arduous applications eg. high temperature environments, submersible operation and high tolerance of corrosive media. www.trolex.com TX5600 Handbook - Vibration TX5600-HV-EN-01 17 3.2 Piezo-resistive Accelerometers Strain gauge technology is employed to monitor the force exerted by a vibrating mass on to a beam. The frequency range of this device is lower than piezo-electric versions, but has the advantage of being able to monitor low frequency vibration down to static or dc acceleration levels. Because of its ability to monitor low levels of acceleration, the piezo-resistive accelerometer is not as robust as piezo-electric devices which limit its application and the costis usually higher. 3.3 Eddy Current Probes Eddy current probes monitor displacement using a non-contacting or proximity method. The eddy current probe is widely used for measuring distances on static and rotating machines. Both the ac vibration and dc gap can be measured by this non-contact method. The simplicity of the probe lends itself to being used in harsh conditions and performs best in very large machines having relatively high levels of displacement. www.trolex.com 18 TX5600-HV-EN-01 3.4 Contact Displacement Sensor There are a number of different types of contact displacement sensors. The most commonly used version being the LVDT type. The use of this type of sensor, is usually limited to specialist applications, and relatively low vibration frequencies where direct contact with the surface being monitored can be accommodated. 3.5 Industrial Applications The overall operating characteristic of piezo-electric sensors are ideally suited to the demanding requirements of heavy industry. They are capable of working reliably for long periods in extreme environments with minimum maintenance, and two basic versions are available for use with a range of monitoring devices to suit any application. www.trolex.com TX5600 Handbook - Vibration TX5600-HV-EN-01 19 3.5.1 ac Output Signal - TX5633 The output signal is a direct millivolt representation of the actual vibration across the complete frequency spectrum range of the sensor. Individual frequency bands relating to discrete components on the machine can be separated and used by a suitable monitoring device to analyse specific faults and changing conditions. A low frequency band selected at the rotational speed of the machine shaft will highlight out of balance problems, debris build up or loose mechanical components. If a second higher frequency band is also defined, then accurate data relating to bearing condition can be monitored or trended to give advanced warning of impending failure as a result of a worn or cracked bearing. This method of vibration monitoring provides very accurate condition data about specific parts of the machine, particularly when it is used in conjunction with monitoring devices that can effectively analyse the data. This range of vibration sensors is available with an ac output voltage compliant with industry standard ICP interface. This provides for precision vibration measurement for machine condition monitoring. These sensors feature: • ac output signal for discreet vibration frequency monitoring RMS indication of acceleration, velocity or displacement • Programmable function and setpoint alarms when used with: TX9137 Programmable Trip Amplifier or TX9042/4 Programmable Sensor Controller • High integrity vibration monitoring for generators, pumps, compressors, turbines and engines • Intrinsically Safe versions available for hazardous areas www.trolex.com 20 TX5600-HV-EN-01 Technical Details Sensing principle Piezo-electric accelerometer Frequency range 1 Hz to 10 kHz Sensitivity range 100 mV/g Linearity +/- 1% Temperature limits -55°C to +110°C Supply voltage 12 V dc Material Stainless steel Protection classification IP67 Mounting M8 x 8 mm mounting stud or Quickfit bush Ex certification EEx ia I Options Cable length to specification MS plug and socket connection Order Reference Vibration Sensor - ac Intrinsically Safe Group I TX5633 www.trolex.com TX5600 Handbook - Vibration TX5600-HV-EN-01 21 3.5.2 dc Output Signal - TX5634 to TX5639 This very similar to the ac output vibration sensor but with an additional built in signal conditioning stage. The raw ac signal of the complete frequency spectrum is averaged into an industrial standard 4 to 20 mA signal, so that low overall vibration levels will generate a 4 mA signal and this will increase linearly as the overall level of vibration increases up to the full scale value of 20 mA. Sensors for use on low speed machines, up to about 1 kHz, are calibrated in terms of acceleration in a choice of measuring ranges from 2 g up to 100 g. Higher speed machines in the 1 kHz to 10 kHz band are best assessed using sensors calibrated in terms of velocity and there is a choice of ranges to suit various applications from 0 up to 100 mm/sec. This type of sensor will accurately monitor the mean level of vibration across the complete frequency spectrum and is very easy to interface with standard industrial control loops. Any general deterioration of the machine condition will show up as a general and overall increase in the level of vibration and this can be used for display purposes or to operate alarm warnings and control devices. This particular sensor is equally useful for indicating that a machine is actually running as it should be. For example, vibration will be absent on a vibrating screen that has failed, so an alarm warning can be initiated. This range of vibration sensors provides a 4 to 20 mA output proportional to a fixed range of either velocity or acceleration. This allows the sensor to be connected to a PLC or other standard monitoring equipment. These sensors feature: • Programmable function and setpoint alarms when used with: TX9131 Programmable Trip Amplifier or TX9042/4 Programmable Sensor Controller • High integrity vibration monitoring for generators, pumps, compressors, turbines and engines • Intrinsically Safe versions available for hazardous areas www.trolex.com 22 TX5600-HV-EN-01 Technical Details Sensing principle Piezo-electric accelerometer Frequency range 1 Hz to 10 kHz Linearity +/- 1% Operating temperature -40°C to +60°C Analogue output 4 to 20 mA Supply voltage 10 to 32 V dc Material Stainless steel Protection classification IP67 Mounting M8 x 12 mm mounting stud or Quickfit bush Ex certification EEx ia I Options Cable length to specification M12 plug and socket connection Order Reference Vibration Sensor - Acceleration Intrinsically Safe Group II General Purpose Intrinsically Safe Group I TX5634 TX5635 TX5636 Vibration Sensor - Velocity Intrinsically Safe Group II General Purpose Intrinsically Safe Group I TX5637 TX5638 TX5639 www.trolex.com TX5600 Handbook - Vibration TX5600-HV-EN-01 23 4. Determining the Right Method Several factors need to be considered when specifying the characteristics of the most suitable vibration sensor to achieve the best performance for a particular application. This is largely dependent upon the type of machine being monitored and the way it functions. The method of mounting the sensor on to the machine is also important and a determination must be made about the type of data that is required from the sensor to drive the chosen monitoring equipment. 4.1 Sensitivity Range of ac Output Accelerometers The sensing element of an ac accelerometer generates an ac voltage output signal, the amplitude of which, is directly proportional to the actual acceleration being experienced by the device as it vibrates. To take the example of a sensor that has a sensitivity of 100 mV/g, this means that if 0.1 g is being measured by the sensor at a particular frequency, it would give an ac output signal of: 0.1 x 100 = 10 mV. The appropriate full scale output range can therefore be selected to match the input range of the monitoring equipment being used. However, the severity of vibration is also a function of the frequency and this factor should be carefully analysed in conjunction with the standard vibration severity tables. 4.2 Sensitivity Range of dc Vibration Sensors In the case of vibration sensors having a standard 4 to 20 mA dc output signal, the collective vibration generated by the machine is averaged across the complete frequency range into an analogue dc signal that is linearly proportional to the general overall level of vibration. The output signal can be calibrated in termsof acceleration or velocity. Acceleration is most widely used with higher range vibration frequency in excess of 1 kHz. Velocity measurement is generally more efficient when monitoring slow moving machinery or shafts operating from 10 Hz up to a maximum of 1 kHz. www.trolex.com 24 TX5600-HV-EN-01 4.3 Frequency Range The frequency range specified for a vibration sensor is the frequency band over which the sensor can effectively operate, and still provide a consistent output signal. It is important to ensure that the operating frequency range of the machine being monitored falls within the capability of the sensor. 4.4 Temperature Range This is the minimum and maximum temperature limits that the sensor can withstand without significantly affecting its response capabilities. This is an important consideration when using the sensor on high temperature equipment or in hot climatic conditions. www.trolex.com TX5600 Handbook - Vibration TX5600-HV-EN-01 25 4.5 Mounting the Sensor Piezo-electric sensors measure vibration mainly in line with the axis of monitoring so it is important that the sensor is installed at the optimum position on the machine. A firm anchor is also essential as incorrect mounting will produce inconsistent data. There are five commonly used sensor mounting methods and each one has a maximum operating frequency that can be monitored. Maximum Operating Frequency Resonant Frequency Stud mount 16 kHz 30 kHz Quickfit stud mount 6 kHz 10 kHz Magnetic mount 7.5 kHz 12 kHz Handheld 800 Hz 1.5 kHz Adhesive mount 9 kHz None Each mounting method also has its own resonant frequency and working in this envelope of vibration should be avoided for best accuracy of response. www.trolex.com 26 TX5600-HV-EN-01 4.5.1 Stud Mount Stud mounting is used for permanently mounted sensor applications. Sometimes, an adhesive will be used in combination with mounting thread to prevent the sensor from losing its torsion under vibration conditions. Stud mounting is not always practical for all applications, but it is the preferred method. In order for the vibration sensor to reproduce precisely the vibration generated by the machine under surveillance, it is imperative that its mounting face, in effect, becomes a solid part of the structure. The sensor mounting face should see a flat surface at the machine interface, any surface irregularities will compromise the correct transmission of vibration. Avoid the common pitfalls below: www.trolex.com TX5600 Handbook - Vibration TX5600-HV-EN-01 27 4.5.2 Quickfit Stud Mount Quickfit stud mounts are also extensively used for collecting data with portable instruments. Repeatability of readings within its acceptable range is good, making it suitable for use with most data collectors. 4.5.3 Magnetic Mount Magnetic mounts are generally used with portable diagnostic instruments when data collecting and will produce repeatable data over its operating frequency range. An alternative to magnetic or portable mounts is to bond a Quickfit bush mount onto the machine. 4.5.4 Handheld This is the least acceptable method of mounting and is only really usable on vibration frequencies below 1 kHz. A handheld probe is of use when other mounting options cannot be used. www.trolex.com 28 TX5600-HV-EN-01 4.5.5 Adhesive Mount Adhesive mounts should be utilised as an alternative to stud mounting where a stud cannot be fitted. Great care should be taken in preparing the surface when using an adhesive, to ensure a permanent bond, because a bad joint will work loose over a period of time. An alternative to magnetic or portable mounts is to bond a Quickfit bush mount onto the machine. The type of adhesive must be appropriate for the materials and the environment in which it is to be used. The adhesive must also provide a rigid base. Soft set adhesive will cause the higher frequencies to be absorbed. 4.5.6 Wiring It is also recommended that the sensor cable is looped and then tied with a cable tie to the main body in order to avoid excessive wear. www.trolex.com TX5600 Handbook - Vibration TX5600-HV-EN-01 29 4.6 Where to Mount the Sensor In order to ensure that vibration problems are diagnosed correctly, it is essential that information received from sensors is representative of the actual vibration on the machine component being monitored. Correct selection of the type of sensor for the vibration being monitored is imperative, but equally important is the mounting location of the sensor on the machine. When monitoring bearings, the sensor should be located as close to the source of vibration as possible. This should be within the load zone of the bearing and is particularly important where high frequency components of vibration are being monitored. Ideally, horizontal and vertical measurements should be taken. However, where cost is critical, a compromise solution of fitting the sensor at 45° to the horizontal can be effective. The sensor should be mounted such that the sensing axis of the sensor passes through the centre of the shaft and as close as possible to the shaft centre line. Readings taken on foundations adjacent to the machine are not representative of shaft and bearing vibration and should only be used when structural vibrations are being monitored. Care should be taken to ensure that the sensor is mounted on a substantial structural part of the machine, such as the motor casing. Avoid mounting on thin sheet metal structures such as outer casings as this can lead to distortion of the data acquired. www.trolex.com 30 TX5600-HV-EN-01 Fitting the sensor to one of the mounting feet of the machine will generally give best results for axial vibration measurement if locations near to the rotating shaft are inaccessible. www.trolex.com TX5600 Handbook - Vibration TX5600-HV-EN-01 31 4.7 Connecting the Sensor Because of the low level of signal produced by most vibration sensors, it is important that good electrical practice is followed in cabling the sensor, on fixed installations. Accelerometers are usually fitted with screened PVC cable encased in an overbraided stainless steel sheath. This offers excellent protection for the arduous environment in which vibration sensors are often used. Long lengths can be difficult to control and movement of the cable itself can contribute to vibration signals. It is recommended that the cable is looped where possible, and secured to the sensor. This also avoids excessive wear and stress at the cable/sensor junction. The cable can be terminated at a local junction box or sensor versions are available with an integral plug and socket connector. In order to avoid electrical pickup through the case of the sensor from the machine being monitored, the machine should be properly earthed in compliance with local regulations. If a good earth is not possible, the sensor and the cable overbraid should be electrically isolated from the machine. www.trolex.com 32 TX5600-HV-EN-01 The screen of the cable should be connected to earth at the monitoring equipment. It should not be earthed at the motor. The cable overbraid should be left unconnected. www.trolex.com TX5600 Handbook - Vibration TX5600-HV-EN-01 33 4.8 Monitoring Equipment The output signal derived from vibration sensors can be interfaced with a variety of monitoring devices to provide simple alarm functions or on line condition analysis of machinery systems. ATEX certified options are also available for use in hazardous areas. The data presented by the vibration sensors falls into two basic categories: 1. An industrial standard 4 to 20 mA signal that is an overall dc average of the complete spectrum of vibration being generated by the machine, this is useful for overall trend analysis and general alarm level monitoring.2. Accelerometers that give an ac voltage representation of the actual vibration across the frequency spectrum being monitored in accordance with the industry standard ICP interface. This can be a powerful diagnostic tool enabling specific frequency bands to be monitored and assessed in exclusive terms. Each type of sensor will require an appropriate monitoring system for optimum performance, and power to drive the sensor will be provided by the selected control and monitoring unit. www.trolex.com 34 TX5600-HV-EN-01 4.8.1 Programmable Trip Amplifier These instruments can be used to provide a readout of vibration level and provide a relay output contact, to alarm when levels exceed a pre-determined value. There are versions to accept the ac signal from vibration sensors as well as the conditioned output from 4 to 20mA sensors. Total programming versatility in a single unit with direct fingertip selection of all input and output control and display functions. • Easy to operate menu programme • Large digital LCD screen with function display and input signal display • Analogue or frequency inputs • Dual set point, relay output • 4 to 20 mA repeater signal • Intrinsically Safe versions available for hazardous areas • Specific frequency boards can be specified when using ac accelerometer sensors for specific monitoring of low or high frequency vibration factors such as shaft rotational speed or high frequency bearing noise www.trolex.com TX5600 Handbook - Vibration TX5600-HV-EN-01 35 Technical Details Temperature limits -5°C to +50°C Display LCD dot matrix, 16 characters Supply voltage 12 V dc (nominal) Input signal capability Current (4 to 20 mA) ac Vibration (1 to 20 kHz) Output relays 2 with programmable set points, time delay hysteresis, rising/falling, latching/pulsing, power on delay, configurable time delay Signal update period 0 to 120 seconds Set point adjustment 0 to 99% Hysteresis adjustment 0 to 99% Information display Menu of standard units (g, mm/s, ft/s, etc.) programmable scale/zero, signal bar graph, set point value display, signal tendency, alarm indicators, signal line monitor, peak/low indicator. Certification EEx ia I Options Repeater output signal (choice of 0.4 to 2 V, 4 to 20 mA or 5 to 15 Hz) DIN rail mount (IP20), Panel mount (IP65) or Rack mount (IP20) Order Reference Programmable Trip Amplifier 4 to 20 mA ac TX9131 TX9137 www.trolex.com 36 TX5600-HV-EN-01 4.8.2 Programmable Trip Amplifier Monitoring up to eight channels of vibration or a combination of condition monitoring sensors. Datalogging and communication facilities allow for trending of vibration. This simplifies monitoring of machine deterioration. Monitors any combination of eight analogue sensors or up to sixteen On/Off digital inputs or frequency inputs. These instruments feature: • Menu operated function selection - scale, units and offset • Four programmable output relays • Simultaneous display of input signal levels • Signal tendency display • Signal bar graph • Peak/low data display • Datacomms for RS232/RS485. TTL digital (MODBUS) • 26,000 point data logging • Intrinsically Safe versions available for hazardous areas • Specific frequency boards can be specified when using ac accelerometer sensors for specific monitoring of low or high frequency vibration factors such as shaft rotational speed or high frequency bearing noise www.trolex.com TX5600 Handbook - Vibration TX5600-HV-EN-01 37 Technical Details Mounting DIN rail, front of panel or 19” rack Display LCD dot matrix, 20 characters x 4 lines. Eight way simultaneous display with individual channel close-up facility Supply voltage 12/24 V dc at 120 mA Input signal capability Current (4 to 20 mA), voltage (0 to 10 V), thermocouple (type J or K), platinum resistance (PT100), bridge (0.1 mV/V to 100 mV/V), digital (on/off), frequency (0.1 Hz to 5 kHz), ac vibration (1 to 20 kHz) Set points 2 per channel, programmable set point level, time delay, hysteresis, rising/falling, latching/pulsing, power on delay Output relays 4, with configurable function grouping Set point adjustment 0 to 99% Hysteresis adjustment 0 to 99% Information display Menu of 30 standard engineering units, (bar, m/s, rpm, etc), programmable scale/zero, signal bar graph, signal tendency, signal fault alarm, peak/low data retention, channel reference text entry Data log 26,000 point data log event recording on each channel Certification EEx ia I Datacomms RS232, RS485. TTL digital Order Reference Programmable Trip Amplifier Group I - Mining General Purpose TX9042 TX9044 www.trolex.com 38 TX5600-HV-EN-01 4.8.3 Distributed Monitoring Multi channel distributed condition monitoring across a wide area network with SCADA base station. • Bus expandable to 256 channels of I/O • Configurable input signals and output drivers • Programmable sensor response functions • Programmable logic control functions • Data logging • Datacomms for distributed systems • Intrinsically Safe for hazardous area operation • Sensor input signal values Individual or multisensor display with signal bargraph trending and text entry for sensor duty • Control output signal status - individual or simultaneous display of output function and text entry for control duty • Data history - data storage of peak/low values and graphical trending. Data logging of sensor data and output events with time, date and identification • Sensor signal function programming Characterisation of sensor response including: rising/falling signal, hysteresis, scaling, units, offset, damping, sample rate and fault monitoring • Datacomms - proprietary Datacomms for distributed monitoring and control systems with conventional or optic fibre transmission - MODBUS • SAP • Ethernet www.trolex.com TX5600 Handbook - Vibration TX5600-HV-EN-01 39 4.8.4 System Analysis It is not always possible to determine the most appropriate type of vibration monitoring that is required on a machine, or it can be difficult to asses the actual vibration levels that are present. It is sometimes necessary to seek specialist advice for a specific system analysis using high accuracy vibration measuring instruments. This service can often form an important part of an on going structured preventative maintenance programme. FFT Programmable Data Collectors FFT analysers enable vibration to be monitored in the frequency spectrum, simplifying diagnosis of machine problems. However, due to cost, these instruments are rarely used for fixed installations. They are usually used as portable instruments to diagnose problems found by overall vibration level analysis instruments. Real-Time Spectrum Analysers Because of the processing power required, most FFT analysers work on stored vibration readings. If real-time monitoring is required, a real-time spectrum analyser should be used. However, their cost and physical size usually prohibits use in all but exceptional circumstances. www.trolex.com 40 TX5600-HV-EN-01 5. Typical Vibration Monitoring Applications 5.1 Underground Booster Fan Monitoring Utilising a Programmable Sensor Controller and the TX5633 Vibration Sensor www.trolex.com TX5600 Handbook - Vibration TX5600-HV-EN-01 41 In the illustration above each sensor signal feeds two independent input channels on the controller. One channel monitors velocity (in mm/s) in the frequency range 10 to 500 Hz. The second channel is configured to monitor acceleration in the frequency range 1 kHz to 20 kHz. The fan is running at 1500 rpm giving a fundamental of 25 Hz. After the fan has been given time to run in, the vibration levels on each channel should be monitored using an FFT analyser to ensure that there are no vibration levels of concern. www.trolex.com 42 TX5600-HV-EN-01Velocity is used to monitor out-of-balance on the fan. This can be due to a number of causes: • Misalignment of the shaft • Imbalance of the blades • Dust build-up on the blades • Chipped or broken blades Acceleration is used to monitor bearing breakdown. This can be a result of a number of conditions, such as lack of lubrication or long term wear and tear. By looking at the trend of velocity and acceleration, the deterioration of the fan, especially with respect to its bearings, can be monitored. As well as monitoring excess vibration levels, the sensors will confirm that the fan is running. A moderate level of vibration, indicates a healthy fan, running at its normal speed. Lack of vibration would indicate a signal fail, or stationary fan. 5.2 Pump Monitoring In this application, two TX5633 sensors are mounted on the outlet end of the pump, one vertical and one horizontal, to monitor: out-of-alignment, mounting movement or loose fixings. www.trolex.com TX5600 Handbook - Vibration TX5600-HV-EN-01 43 The TX5633 sensors are connected to two channels of the Programmable Sensor Controller which is set-up to monitor velocity in the range 10 to 500 Hz. The pump is rotating at 3000 rpm giving a fundamental frequency of 50 Hz. Alarm levels on the Programmable Sensor Controller are set up according to BS7854 Part 1, (ISO10816-1) to monitor vibration severity. www.trolex.com 44 TX5600-HV-EN-01 As the Programmable Sensor Controller has spare channels available, temperature and pressure monitoring on the pump can easily be accommodated using simple PT100 probes and pressure sensors. www.trolex.com TX5600 Handbook - Vibration TX5600-HV-EN-01 45 5.3 Vibration Monitoring in Hazardous Areas When the machinery to be monitored is in a hazardous area, certified safe equipment needs to be used. TX5630 Vibration sensors are certified, Intrinsically Safe, for use in Group II hazardous areas. However, Trolex monitoring equipment is intended for mounting in the safe area. In order to connect to the sensors in the hazardous area, zener safety barriers or isolators need to be used between the sensors and the monitoring equipment. The diagrams below give typical barrier and isolator options. www.trolex.com 46 TX5600-HV-EN-01 5.4 Screening and Bunker Outfeed Monitoring Vibratory screens are used for the grading of product in many mining and quarrying applications. Product is introduced onto a vibrating sieve and small product passes through whilst large product is screened to the next stage. Vibrating pans are used on the outfeed to ensure that product does not block the outfeed chutes. A Trolex TX5630 Vibration Sensor mounted on the vibratory screen, can monitor the operation and condition of the screen, when connected to a Programmable Sensor Controller. Upper and Lower alarms can monitor that the screen is running correctly and that vibration levels are not excessive. By trending vibration levels, deterioration in the condition of the screen and its mounts can be monitored. Similarly, the vibrating pans on the outfeed can be monitored for both operation and excessive wear. www.trolex.com TX5600 Handbook - Vibration TX5600-HV-EN-01 47 5.5 Conveyor Drive Monitoring A conveyor is the backbone of any product clearance system and a breakdown of this is likely to be costly. Utilising vibration monitoring equipment, the plant engineer can obtain an early indication of impending motor and gearbox failure. Temperature monitoring can also be utilised to save catastrophic failure by interlocking an excessive temperature alarm setpoint with the motor drive control. The following diagram shows how the vibration sensors and temperature sensors connected to a Programmable Sensor Controller and how this could be used to disable the conveyor under high temperature conditions or excessive vibration. www.trolex.com 48 TX5600-HV-EN-01 NAMUR sensors can be used to indicate conveyor speed and belt slip, by monitoring the speed of both the motor and an idler wheel. If the temperature inputs are programmed to latch one of the output relays when over temperature occurs, the output relay could be interlocked with the conveyor stop circuitry to lockout the conveyor. The latched relay would then have to be manually reset before attempting to restart the machine. An input from the conveyor drive contactor can give confirmation that the conveyor is running. www.trolex.com TX5600 Handbook - Vibration TX5600-HV-EN-01 49 6. Interpreting Vibration Data An example is given below to demonstrate how vibration how vibration can be used to monitor bearing and gearmesh deterioration and imbalance on a ventilation fan. Ventilation fans are used in critical areas such as underground mining and tunnelling, where natural ventilation is not sufficient to either dilute noxious/ explosive gases or to ensure a sufficient supply of oxygen. There are 3 areas of interest in monitoring vibration on the above installation. Although these areas are not always as discreetly defined as shown here, they have been separated for the purposes of this example. www.trolex.com 50 TX5600-HV-EN-01 www.trolex.com TX5600 Handbook - Vibration TX5600-HV-EN-01 51 6.1 Imbalance Imbalance occurs because the machine is not perfectly balanced about the shaft centre line. This can be caused during manufacture, installation or during operation (eg. debris build-up on a fan blade). Imbalance will occur at the rotational frequency of the fan. So on a fan rotating at 1500 rpm, imbalance will occur at 25 Hz. As the imbalance increases, it will be seen as increase in the vibration signal at 25 Hz. This will require a monitoring instrument capable of displaying the signal in the frequency domain (eg. FFT analyser). If a broadband alarm monitor, such as the Programmable Sensor Controller is used, with a fixed, low pass filter then the general overall level of vibration will be seen to increase. This can be compared to an alarm set-point, as suggested by BS7854 Part 1. This alarm indication would suggest that a spectrum analyser should be employed to define the fault more specifically. 6.2 Gearmesh Problems Vibration due to the gear teeth will be seen at the rotational frequency multiplied by the number of teeth. So, on a machine with rotational frequency 1500 rpm and 30 teeth on the wheel, the fundamental vibration frequency is about 750 Hz. As the teeth start to deteriorate, the amplitude of the vibration, at the 750 Hz fundamental, will increase. This would easily be picked up with an instrument such as an FFT analyser. An alarm instrument such as a Programmable Sensor Controller, could also be used to indicate that the level of vibration, around the frequency of interest, has increased. www.trolex.com 52 TX5600-HV-EN-01 6.3 Bearing Breakdown Bearing noise, due to imperfections in the bearing, will start at high frequency (>1 kHz). Bearing deterioration can be caused by: • Poor quality of the bearing • Inadequate lubrication • Contaminated lubrication • Poor installation As the bearing starts to deteriorate, larger imperfections occur, increasing the amplitude of the vibration and at the same time reducing the frequency of the vibration. Over time, the signal will change as shown in the illustration below. A Programmable Sensor Controller can be used to monitor the increase in broadband vibration, whilst disregarding the change in frequency. www.trolex.com TX5600 Handbook - Vibration TX5600-HV-EN-01 53 Disclaimers The information provided in this document contains general descriptions and technical characteristics of the performance of the product. It is not intended as a substitute for and is not to be used for determining suitability or reliability of this productfor specific user applications. It is the duty of any user or installer to perform the appropriate and complete risk analysis, evaluation and testing of the products with respect to the relevant specific application or use. Trolex shall not be responsible or liable for misuse of the information contained herein. If you have any suggestions for improvements or amendments, or find errors in this publication, please notify us at marketing@trolex.com. No part of this document may be reproduced in any form or by any means, electronic or mechanical, including photocopying, without express written permission of Trolex. All pertinent state, regional, and local safety regulations must be observed when installing and using this product. For reasons of safety and to help ensure compliance with documented system data, only Trolex or its affiliates should perform repairs to components. When devices are used for applications with technical safety requirements, the relevant instructions must be followed. Trademarks © 2014 Trolex® Limited. Trolex is a registered trademark of Trolex Limited. The use of all trademarks in this document is acknowledged. Document History Issue 01 19 June 2014 Original publication of this document Contact Details Trolex Ltd, Newby Road, Hazel Grove, Stockport, Cheshire, SK7 5DY, UK +44 (0) 161 483 1435 sales@trolex.com www.trolex.com
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