MONARCH INSTRUMENT
Instruction Manual
EXAMINER 1000
MONARCH INSTRUMENT
15 Columbia Drive
Amherst, NH 03031 USA
Phone: 603-883-3390
Fax: 603-886-3300
www.monarchinstrument.com
e-mail: sales@monarchinstrument.com
Printed in the U.S.A. © Monarch Instrument 2001 all rights reserved
1071-4400-112
EXAMINER 1000 SPECIFICATIONS
Vibration Sensor: Piezoelectric accelerometer 100 mV/g with magnetic base, probe
and 5 foot cable to BNC
Display: LCD 3.5 digit , measurement, hold, low battery indicator
Measurement Acceleration 0.01-19.99 g (RMS)
Range: Velocity 0.01-19.99 in/sec., 0.1-199.9 mm/sec (RMS)
Envelope 0.01-19.99 ge (peak)
Frequency Range: Overall 10 Hz - 10 kHz
Envelope 0.5 kHz-10 kHz
Output: Sensor Excitation: 12 Vdc @ 2 mA (BNC)
Audio Out: 3.5 mm mini plug; 250 mW into 8 ohms, 150 mW into
32 ohms; Adjustable volume control with off position
Power: (2) “AA” cells
Operating Time: 20 hours continuous without headphones
Weight: Instrument: 7 oz. (0.19 kg); Complete Kit: 2.85 lb (1.30 kg)
Dimensions: 6.3 x 3.3 x 1.25” (152 x 83 x 32 mm)
Operating conditions: -14° to 122°F (-10° to 50°C)
ISO 2372 (10816) Standards provide guidance for evaluating vibration severity in
machines operating in the 10 to 200 Hz (600 to 12,000 RPM) frequency range.
Examples of these types of machines are small, direct-coupled, electric motors and
pumps, production motors, medium motors, generators, steam and gas turbines,
turbo-compressors, turbo-pumps and fans. Some of these machines can be coupled
rigidly or flexibly, or connected through gears. The axis of the rotating shaft may
be horizontal, vertical or inclined at any angle. Use the chart below combined with
additional factors described in this manual to judge the overall vibration severity of
your equipment.
VIBRATION SEVERITY PER ISO 2372 (10816)
Vibration Velocity Vrms
good
satisfactory
unsatisfactory
unacceptable
Machine Class I Class II Class III Class IV
small medium large rigid large soft
in/s mm/s foundation foundation
0.01 0.28
0.02 0.45
0.03 0.70
0.04 1.10
0.07 1.80
0.11 2.80
0.18 4.50
0.28 7.00
0.44 11.0
0.71 18.0
1.10 28.0
MONARCH INSTRUMENT
Service Policy, Warranty, Disclaimer and Limit of Remedies
Except for the limited warranty described below, there are no warranties, expressed or
implied, including but not limited to, the implied warranties of merchantability and
fitness for a particular purpose: all such warranties are expressly and specifically disclaimed.
EXAMINER 1000 is guaranteed free from defects in material and workmanship. Mechanical components, transducers, and cable assemblies are guaranteed for a period of
(90) days. Electronic components are guaranteed for a period of (12) months. The
warranty period begins on the date the products are shipped from the Monarch Instrument factory or an Authorized Distributor.
This warranty does not extend to units that have been misused, altered, or repaired
without manufacturer’s authorization. Defects or failures experienced during the warranty period will be corrected at no charge at the manufacturer’s facility. If, upon
examination, it is found that the defect is not within the scope of this warranty, an
estimate of repair charges and a request for authorization to proceed with the repair
will be submitted, along with a statement of the reasons the repairs are not considered
to be covered by the warranty.
This warranty does not extend to system components such as transducers, headphones
and cable assemblies manufactured by others. Warranty for these components will be
their manufacturer’s standard.
Manufacturer’s liability under this warranty is limited to repair or replacement of any
defective instrument at the discretion of the manufacturer. In the event that any of the
above limitations are held unenforceable, our liability to you shall not exceed the
purchase price paid for the product, regardless of the claim. Because of the diverse
ways that the product can be used, you are advised to test the product for suitability of
use for your purposes prior to relying on it.
MONARCH INSTRUMENT
15 Columbia Drive
Amherst, NH 03031 USA
Phone: 603-883-3390
Fax: 603-886-3300
www.monarchinstrument.com
e-mail: sales@monarchinstrument.com
OPERATING THE EXAMINER 1000
Overview ........................................................................... 1
Controls and Functions........................... ........................... 1
Rear Panel, Batteries and Connections ............................. 2
Parts of the System ........................................................... 3
Overview of Data Collection Procedure.............................. 3
APPLYING THE EXAMINER 1000
What is Predictive Maintenance? ....................................... 4
Benefits of Predictive Maintenance .................................... 4
Why Measure Vibration? .................................................... 5
Selecting Machinery & Measurements................................ 6
Selecting Measurement Types ........................................... 7
Getting Started in your Plant............................................... 8
Establishing a Data Collection Route.................................. 9
What are you Measuring? .................................................. 10
Measurement Techniques .................................................. 11
Evaluating overall Vibration Measurements ........................12
Evaluating Acceleration Envelope Measurements...............13
GLOSSARY ........................................................................14
TABLE OF CONTENTS
TABLE OF CONTENTS
GLOSSARY (for vibration purposes)
Piezoelectric A material in which electrical properties change when subjected
to force.
Process Measurements Variables such as temperature, pressure, speed and
flow used to assess internal conditions of efficiency.
Radial Direction perpendicular to the shaft centerline.
Repeatability A measure of the deviation between successive measurements made
under the same conditions.
RMS Peak Vibration x .707. ( in/s or mm/s)
Rolling Element Bearing A bearing consisting of balls or rollers operating be-
tween fixed and rotating races.
Route A sequence of measurements arranged for convenience
during acquisition.
Sensitivity Used to describe a transducer’s electrical output for a unit varia-
tion of the mechanical quantity measured.
Stress Force per unit area
Synchronous Frequency components that are an integer multiple of
running speed.
Transducer A system consisting of a sensor and signal conditioner to convert
a physical quantity into an output for display, monitoring
and analysis.
Transmission Path The path from source (excitation) to sensor.
Trending The plot of a variable over time used as an indicator of change.
Velocity A vector quantity of the time rate change of displacement.
15
Vibration Conversions
D = 19.10 x 103 x (V/F)
D = 70.4 x 106 x (A/F2)
V = 52.36 x 10-6 x D x F
V = 3.68 x 103 x (A/f)
A = 14.2 x 10-9 x D x F
2
A = 0.27 x 10
-3
x V x F
where: D = Displacement (mils peak-to-peak)
V = Velocity (in/s zero-to-peak)
A = Acceleration (in/s2 zero-to-peak)
F = Frequency (cpm)
OPERATING THE EXAMINER 1000
Overview
The EXAMINER 1000 is designed in conjunction with vibration limits established in ISO Standards 2372(10816)/3945 to help you detect signs of malfunction
or changes in rotating machinery during operation. This is accomplished with overall
vibration (ISO VIB) and envelope measurements. Problems with bearings occur
when there is a microscopic crack or flaw or when there is a breakdown in lubrication which leads to metal-to-metal interaction. The EXAMINER 1000 is designed
to detect flaws or a lack of lubrication in bearings and gears at an early stage by
measuring the high-frequency impacts through acceleration envelope methods.
Vibration measurements are made by pressing the accelerometer sensor against
designated Measurement Points on your equipment with either the stringer probe
or with the magnetic base.
Controls and Functions
ON/SELECT Button - Press this button to turn power on. Power automatically
turns off after ten minutes of non-use. After turning the EXAMINER “on”, press
the ON/SELECT button again to select the measurement type. Pressing and hold-
ing the ON/SELECT button while collecting data will HOLD the display value,
indicated by the word “HOLD” in the display. To release from HOLD mode, press
the ON/SELECT button again.
DISPLAY- The digital display shows the numerical value of the measurement. An
arrow indicates the measurement type selected. The units of vibration are automatically displayed as the type of measurement is selected. The user may work in
either metric or imperial units in the V-velocity mode.
1
Type of
Measurement
Value of Measurement
Units of
Measure
0.09
g
GE
in/s
mm/s
V
A
E
LoBat
HOLD
Low Battery
Indicator
Type of Measurement
Indicator
Hold Reading
Indicator
GLOSSARY (for vibration purposes)
Acceleration A vector quantity that specifies time rate of change of velocity.
Expressed in either g’s or m/sec2 where 1 g = 386.1 in/sec2 and
9.8066 m/sec2.
Acceleration Enveloping A high-frequency, filtered data collection method ex-
pressed in ge.
Accelerometer A transducer which converts acceleration motion in to an
electrical output.
Amplitude The magnitude of vibratory motion. Can be measured as peak-to-
peak, zero-to-peak, or RMS.
Axial The direction parallel to the axis of rotation.
Baseline Recorded values taken when a machine is know to be good. The
standard which all additional readings will be compared to.
CPM Unit of frequency measurement-cycles per minute.
Displacement A vector quantity specifying the change of position of a body mea-
sured from the resting position.
Dynamic Force A force that varies with time.
Force Energy applied to a mass producing a deflection (static force) or
motion (dynamic force).
Frequency The repetition rate of a periodic event, expressed in cycles per
second (Hz), CPM, RPM, or multiples of running speed (orders).
g’s Units of acceleration produced against the force of gravity.
(1g=32.1739 ft./sec/sec; 1g=9.8066 m/sec/sec)
Gear Mesh Frequency A frequency generated by a gear. Defined as the number
of gear teeth on a gear times its shaft-rotating frequency.
Hertz (Hz) A unit of frequency measurement, cycles per second.
High-pass Filter A filter that allows only those components above a selected fre-
quency to pass.
Integration The time-based process of converting acceleration and velocity to
velocity or displacement.
in/sec, ips Abbreviations for inches per second, a measure of velocity.
Mass The measure of body resistance to acceleration. Proportional to,
but not equal to, weight (mass = weight/gravity).
Measurement Point A location on a machine or component where all subsequent
measurements should be made for accurate comparison.
Mechanical Impedance Ratio of applied force to resulting velocity during
simple harmonic excitation.
Overall The amplitude of vibration within a specified frequency range.
Peak Value The absolute value zero to the maximum excursion on a dynamic
waveform. Also true peak and zero-to-peak.
Periodic Monitoring Measurements recorded at intervals of time.
14
2
BATTERY
COMPARTMENT
Contains two “AA”
alkaline batteries.
REAR PANEL CONNECTIONS
AUDIO OUT SENSOR IN
CONNECTIONS
QUICK REFERENCE
INSTRUCTION
PANEL
PRODUCT SERIAL
NUMBER
AUDIO OUT
1/8” (3.5 mm)
stereo mini plug
SENSOR INPUT
BNC Connector
output 12 vdc @ 2 mA
VOLUME
CONTROL
TOP VIEW
E X A M I N E R
1 0 0 0
VIBRATION METER
ELECTRONIC STETHOSCOPE
REFER TO OPERATORS MANUAL
FOR INSTRUCTIONS
CONNECTIONS
SENSOR IN AUDIO OUT
Measurement Types Units
V velocity mm/s in/s
A acceleration g
E envelope ge
Monarch Instrument
15 Columbia Drive
Amherst, NH 03031 USA
Trend Comparison
The most efficient and reliable method of evaluating vibration severity is to compare the most recent reading against previous readings for the same measurement
Point, allowing you to see how the Point’s vibration values are “trending” over
time. This trend comparison between present and past readings is easier to analyze
when the values are plotted in a “trend plot”. A trend plot displays current and past
values plotted over time. Measurement records should also include a baseline (known
good) reading. The baseline value may be acquired after an overhaul or when other
indicators show that the machine is running well. Subsequent measurements are
compared to the baseline to determine machinery changes.
Comparison with Other Machinery
When several similar machines are used under the same operating conditions, evaluation can be carried out by measuring all machines at the same Points and comparing the results.
Evaluating Acceleration Envelope Measurements
Use the same techniques of comparison as for Overall Vibration readings. Remember, acceleration envelope is an advanced “early warning” of a developing problem. High values do not necessarily indicate bearing failure. They can
also indicate:
A. Lack of lubrication or decreasing oil viscosity due to high bearing tem-
perature caused by overload or external heat source.
B. Breaking of the lubricant film by excessive imbalance, misalignment,
or housing deformation. Loss of boundary lubrication.
C. A rubbing seal or cover.
D. Gear mesh interaction (bad lubrication, defects)
E. Dirt or particles in the lubricant, or a seal or filter problem.
Use trend Comparison similar to overall vibration to establish severity levels.
Accelerating Envelope readings tend to decrease as Overall Vibrations readings
increase. This happens when the defect in the bearing is becoming more severe and
the frequency it generates becomes lower which makes it better read with the
Velocity-type readings.
Audio Comparison with Other Bearings on the Same Machinery
When several bearings are used under the same operating conditions, evaluation
can be carried out by listening to the audio signals to determine changes. This
method will help to locate the defective bearing quickly. Measure all machines at
the same Points and compare the results. Listen for increases in signal and for
“clicking” patterns which indicate wear.
13
Overview of Data Collection Procedure
1. Press the ON/SELECT button.
2. Press the ON/SELECT button again to select the desired measurement type.
Place the accelerometer sensor on the machinery Measurement Point (use proper
probe technique as discussed on the following pages).
3. Wait for the reading to stabilize, then press and hold the ON/SELECT button
to “HOLD” the measurement. Indicated by HOLD in the display.
4. Adjust headphones volume level and listen for any distinct patterns or noises.
5. Record the measurement value in your Machinery Data Worksheet.
6. To release the HOLD function, press ON/SELECT again.
7. Repeat the above steps for each Measurement Point.
3
Parts of the System
EXAMINER 1000 METER
ACCELEROMETER
WITH CABLE
HEAD PHONES
MAGNETIC BASE
STINGER PROBE
HOLSTER
ON-TIME SOFTWARE AND
OWNERS MANUAL (optional)
Evaluating the Overall Vibration Measurements
Three general principles are commonly used to evaluate your vibration measurement values:
ISO 2372 (10816) Standard Comparison - Compare values to the limits estab-
lished in the ISO 2372 (10816) Standard.
Trend Comparison - Compare current values with values of Baseline for the same
Points over a period of time.
Comparison with Other Machinery - Measure several machines of a similar type
under the same conditions and judge the results by mutual comparison.
If possible, you should use all three comparisons to evaluate your machinery’s
condition. ISO 2372 (10816) and trend comparisons should always be used.
ISO 2372 (10816) Standard Comparison
The ISO 2372 (10816) Standards provide guidance for evaluating vibration severity in machines operating in the 10 to 200 Hz (600 to 12,000 RPM) frequency
range. Examples of these types of machines are small, direct-coupled, electric motors
and pumps, production motors, medium motors, generators, steam and gas turbines, turbo-compressors, turbo-pumps and fans. Some of these machines can be
coupled rigidly or flexibly, or connected through gears. The axis of the rotating
shaft may be horizontal, vertical or inclined at any angle.
Machinery class designations are:
Class l
Individual parts of engines and machines, integrally connected with the complete
machine in its normal operating condition. (Production electrical motors of up to
20 HP (15 kW) are typical examples of machines in this category.)
Class ll
Medium-sized machines typically, electric motors with 20 to 75 HP (15-75 kW)
without special foundations, rigidly mounted engines, or machines on special foundations up to 400 HP (300 kW).
Class lll
Large prime movers and other large machines with rotating masses mounted on
rigid and heavy foundations which are relatively stiff in the direction of vibration
measurement.
Class lV
Large prime movers and other large machines with rotating masses mounted on
foundations which are relatively soft in the direction of vibration measurement (for
example, turbo-generator sets, especially those with lightweight ub-structures).
Note: These ISO 2372 (10816) Standard classes do not apply to prime movers or driven
equipment in which the major working components have a reciprocating motion.
12
What Is Predictive Maintenance?
Predictive Maintenance can be defined as collecting information from machines as
they operate to aid in making decisions about their health, repair and possible improvements in order to reach maximum runability, before any unplanned breakdown. Machinery maintenance has evolved because of the demands to become
more profitable through reduced maintenance costs. Below is the progression of
these maintenance philosophies:
• Break Down Maintenance
• Preventive Maintenance
• Predictive Maintenance
Break Down Maintenance occurs when repair action is not taken on a problem
until the problem results in the machines failure. Run to failure problems often
cause costly secondary damage along with expenses resulting from unplanned downtime and unplanned maintenance.
Preventive Maintenance occurs when a machine, or parts of a machine, are overhauled on a regular basis regardless of the condition of the parts. While better than
run to failure, preventive maintenance results in excessive downtime due to unnecessary overhauls and the excessive costs of replacing good parts along with worn
parts.
Predictive Maintenance is the process of determining the condition of machinery
as it operates, to predict and schedule the most efficient repair of problem components prior to failure. Predictive Maintenance not only helps plant personnel eliminate unplanned downtime and the possibility of catastrophic failure, but allows
them effectively order parts, schedule manpower, and plan multiple repairs during
scheduled downtime.
Benefits of Predictive Maintenance
Documented experience proves that plants which establish a predictive maintenance program are able to:
• Improve Machinery Reliability-reduced “unplanned failures”
• Reduce Maintenance Costs-knowing the exact problem to fix
• Increase Production-optimize machinery capabilities
• Lower Energy Consumption- less vibration usually means less friction
• Extend Bearing Service Life- reduce vibration and lubrication failures
• Improve Product Quality- where less vibration improves finish
The benefits are numerous and will vary depending upon the implementation of
your Predictive Maintenance Program.
411
Measurement Techniques
In general, vibration of anti-friction bearings is best monitored in the load zone of
the bearing. Equipment design often limits the ability to collect data in this zone.
Simply select the measurement Point which gives the best signal. Avoid painted
surfaces, unloaded bearing zones, housing splits, and structural gaps. When measuring vibration with a hand-held sensor, it is very important to collect consistent
readings, paying close attention to the sensor’s position on the machinery, the
sensor’s angle to the machinery, and the contact pressure with which the sensor is
held on the machinery.
• Location - always collect at the same point on the machine. Mark locations.
• Position - Vibration should be measured in three directions:
A axial direction
H horizontal direction
V vertical direction
• Angle - Always perpendicular to the surface (90o +10o).
• Pressure - Even, consistent hand pressure must be used (firm, but not
so firm as to dampen the vibration signal). For best results
use the magnetic base. If using the stinger/probe is the only
method available to collect data, it is best to use a punch to
mark the location for the probe-tip to ensure a consistent
coupling to the housing.
Optimum Measurement Conditions
Perform measurements with the machine operating under normal conditions. For
example, when the rotor, housing, and main bearings have reached their normal
steady operating temperatures and with the machine running under its normal rated
condition (for example, at rated voltage, flow, pressure and load). On machines
with varying speeds or loads, perform measurements at all extreme rating conditions in addition to selected conditions within these limits. The maximum measured value represents the vibration severity.
load zone
Magnetically
Mounted
Vibration Sensor
Stinger Mounted
Vibration Sensor
5
Why Measure Vibration?
Vibration is considered the best operating parameter to judge dynamic conditions
such as balance (overall vibration), bearing defects (enveloping) and stress applied
to components. Many machinery problems show themselves as excessive vibration. Rotor imbalance, misalignment, mechanical looseness, structural resonance,
soft foundation, and gearmesh defects are some of the defects that can be measured
by vibration. Measuring the “overall” vibration of a machine, a rotor in relation to
a machine or the structure of a machine, and comparing the measurement to its
normal value (norm) indicates the current health of the machine.
The EXAMINER 1000 measures the vibration of a machine while it is operating.
Trending these measurements shows how a machine’s condition changes over a
period of time. Analyzing these, along with other measurements, provide insight
into the condition of the machine and which components may be wearing or failing. How to best monitor a machine’s condition requires one to know which measurements to take and where and how to take them. Sensors are placed at strategic
Points on the machinery to monitor the machine’s condition.
The EXAMINER 1000 processes the accelerometer’s mechanical vibration en-
ergy into an electrical signal and displays the measurement value in numerical
form for evaluation. Commonly measured physical characteristics in Predictive
Maintenance are:
• Vibration (as explained above)
• Temperature
• Oil Analysis
Temperature
As a bearing fails, friction causes its temperature (or its lubricant’s temperature) to
rise. While trending a bearing if the temperature rises followed by a vibration increase, then it is safe to conclude their was a loss of lubrication which induced the
mechanical failure. If vibration increased first, followed by increased temperature
readings then a mechanical defect caused the lubrication failure.
Lube Oil Analysis (Ferrography)
Monitoring oil condition warns of an increase in foreign substances, such as water,
which can degrade the lubricating properties of the oil and cause bearing failures.
It also detects the presence of metallic particles carried into the oil stream. These
metallic particles are analyzed to determine which part of the machine is wearing
and how fast. Lubrication analysis is the earliest warning of a developing problem.
Lube oil testing results can be trended with On-Time software.
What are you Measuring?
Vibration is the behavior of a machine’s mechanical components as they react to
internal or external forces. Since most rotating machinery problems show themselves as excessive vibration, we use vibration signals as an indication of a machine’s
mechanical condition. Also, each mechanical problem or defect generates vibration in its own unique way. We therefore analyze the “type” of vibration to identify its cause and take appropriate repair action. With overall vibration monitoring
(VIB ISO) using the Examiner 1000, analysis of the cause of excess vibration
relates to the monitoring equipment’s probe position; either horizontal, vertical, or
axial.
Horizontal - Typically, unbalanced shafts tend to cause excess radial (horizontal
and vertical) vibrations, depending on the machine support design.
Vertical - Excessive vertical vibration can indicate mechanical looseness as well
as imbalance.
Axial - Excessive axial vibration is a strong indicator of misalignment.
It’s important to note that these are general guidelines and that knowledge of your
machinery and proper hand-held probe techniques are necessary to accurately analyze the cause of excessive vibration.
Multi-Parameter Monitoring
Using different measurement types to monitor your machinery for changes. This
allows for early detection of specific machinery problems that may not show under
normal overall vibration monitoring. For example, if a rolling element bearing has
a defect on its outer race, each roller will strike the defect as it goes by and cause a
small, repetitive vibration signal. However, this vibration signal is of such low
amplitude that under normal overall vibration monitoring, it is lost in the machine’s
rotational and structural vibration signals. Acceleration Enveloping can measure
these signals better than overall readings. Use both measurement types for bear-
ings and gearboxes. As ENV values begin to decrease, rely on VEL readings.
Overall Vibration Monitoring -Monitors normal, low frequency machine vibra-
tion. Detects rotational and structural problems like imbalance, misalignment, and
mechanical looseness.
Enveloping - Amplifies high-frequency, repetitive bearing and gear mesh vibration signals for early detection of bearing problems, but does not detect non-repetitive
rotational or structural events like imbalance, misalignment, and looseness. Provides earliest detection of high frequency metal-to-metal contact or poor lubrication in problem bearings.
10
6
Selecting Machinery and Measurements
Maintenance personnel have always made visual and hands-on inspections of their
machinery on a periodic basis. Systematic data collection and trending allows for
recall and comparison of events over time but is not a replacement for good maintenance practices. Collecting machinery data is an aid to the maintenance professional, which is used in addition to good maintenance practices.
Selecting and Classifying Machinery
Setting up an effective Predictive Maintenance Program requires a careful study of
the needs of the plant. It is necessary to know each machine and its response to
change. The following is an example of machinery classification:
Critical Machines expensive premium equipment, generally >500 HP. Usually
less than 5% of all plant equipment. Maintenance dollars per horsepower per year
average $11.00. This category of equipment is very well maintained and monitored. Continuous monitoring systems are better suited for this type of equipment.
Essential Machines medium size equipment, 100-500 HP. This group may be 3040% of all the equipment in the plant. Maintenance costs can average $22.00 per
horsepower per year. Less attention is paid to these machines even though their
repair costs can be as high as critical machines. Select some of these machines for
your Predictive Maintenance Program.
Redundant Machines small redundant equipment usually < 100 HP. This group
can be as much as 50% of all machines in a plant and yet they are usually neglected. By far the most expensive to maintain at $49.00/HP/year, this group will
benefit the most from Predictive Maintenance practices. At many facilities, this
group consumes 80% of the annual maintenance budget. If you want to have an
immediate impact begin with these machines. Also include machines with known
problems or a history of problems. Personnel Safety is always the first priority in
selecting machinery to monitor.
CRITICAL
ESSENTIAL
REDUNDANT
Machine Identification Water Pump #707
Machine Description AC motor 1800 RPM, flexible
coupling, 3 vane pump. CAUTION HOT WATER!!!
Date Point Direction Type Value
Jan 2 1999 A V V 0.06 in/s
Jan 2 1999 A H V 0.04 in/s
Jan 2 1999 A X V 0.03 in/s
Jan 2 1999 B V V 0.07 in/s
Jan 2 1999 B H V 0.05 in/s
Jan 2 1999 B V Env 0.001 ge
Establishing a Data Collection Route
The Machinery Data Worksheet helps organize data for routine data collection.
Vibration readings are taken on the Points (bearings) established in your route and
recorded using your naming convention on the worksheet. Vibration, speed, temperature, pressure or any process data may be recorded using this type of systematic approach.
Steps for Route collection
1. Determine the machines which require data collection.
2. Define each measurement type for data collection Points on each Machine.
Several Points will have numerous readings i.e. VEL and ENV and Temp.
3. Establish a Route with the Machines grouped by physical location.
4. Walk the Route, collecting and recording data for each Point.
5. Transfer data values to your On-Time Trending software.
Recording Data for a Machine
234
5
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5
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BCD
MOTOR PUMP
A
The vibration sensor is
placed on each data collection Point. The Point,
direction of the sensor
and the value are recorded on the Machinery
Data Worksheet.
Point AVV is
taken on the outboard end of the
motor, in the vertical position
with a velocity
type reading.
AHV -Point A in
the horizontal position with a Velocity type.
9
example of Machinery Data Worksheet
Selecting Measurements
Establish measurement types that most accurately reflect the condition of the equipment. Different causes or “mechanisms” are acting on the machine; various types
of measurements have been developed to measure each type of mechanism. Those
mechanisms are:
Stress
A force on the machine or components which deflects the part. Best measured in Displacement. The Examiner 1000 does not measure Displacement as it is a very low vibration frequency, below 10 Hz (600 RPM).
Fatigue Repeated cycles of stress on a component. If you bend a part back and
forth enough times it will fatigue. As a general rule, fatigue failures
result from vibration frequencies 10 -2000 Hz and Velocity measurements are used. Velocity will be the primary measurement taken.
Force Mass x acceleration. Measured in Acceleration. Acceleration is the rate
of change of velocity. Acceleration is used for high frequencies above
2000 Hz (120,000 RPM). Bearing defects and gearmesh frequencies are
usually found in this range.
Impact forces The result of fatigue. Impact forces are cyclical events which can
be detected with Acceleration Enveloping. These are high frequency-low amplitude events and a filter in the EXAMINER 1000
is set at 10-30 kHz to measure them.
Types of Measurements in the EXAMINER 1000
Velocity- Good for frequency ranges 10-2000 Hz (600-120,000 RPM).
Acceleration-used for higher frequencies or speeds above 2000 Hz (120,000 CPM).
Acceleration Enveloping-uses a high pass filter to measure high-frequency, re-
petitive bearing and gearmesh vibration signals. Used for early detection of developing bearing or lubrication problems. Use this type in combination with the other
types to detect changes in machinery.
Select Measurement Intervals
Based on the classification of the machine, its repair history and the amount of data
required for a detailed trend analysis. At the beginning of a Predictive Maintenance Program, collect data frequently to build a rapid history of each machine.
Adjust your program as you go. If measurement results are indicating signs of
change, measurements should be performed more frequently.
7 8
Getting Started in Your Plant
Planning your work is very important to achieve success. The EXAMINER 1000
is an overall vibration meter and electronic stethoscope. It can be used as a stand
alone device for the collection of vibration data for the purposes of trending or as a
diagnostic instrument used to troubleshoot machinery defects. In order to setup a
trending program you must collect data on the same point with the same measurement type at a defined interval. The Machinery Data Worksheet allows for record
keeping of collected data. The EXAMINER may be used with the On-Time software to store data and perform trend analysis. REPEATABILITY IS REQUIRED
FOR ACCURATE TRENDING.
Establish a standard naming convention so you can communicate your results to
the rest of maintenance. Vibration readings are taken on the bearing caps or as
close to the bearings as possible. Always collect data the same way, at the same
point on the machine each time.
Horizontal
Axial
Direction for placing the Sensor
For Vertical and Horizontal readings, the
sensor is placed in a radial position.
Also establish a starting point for each machine. Begin from the OUTBOARD
END of the DRIVE UNIT, calling this point A. Proceed to label Points (bearings)
as needed until you have reached the outboard end of the driven unit.
POINT
A
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234
5
234
5
234
5
234
5
234
5
234
5
234
5
BCD
MOTOR PUMP
Vertical
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