Machinery Vibration - Assignment Example

Running Head: Machine Vibration Question 1: Comprehensive Information on Critical Machine With today’s complicated business situation, it’s more vital to know how is your recycling plant working (Cassidy, 2005). It’s also essential to shun sudden costly breakdowns, and also to keep the plant downtime work to the lowest quantity. This is chiefly hard in crumb auto recycling business, where all machines should be able to handle huge vehicle along with a good throughput. The apparatus takes battering & either now or then it should be managed or it shall break down. Although it is achievable to construct some severance into an action –like as having extra scrap usage crane. There’s often only 1 shredding mechanism at the centre heart of the auto shred plant. If that shredder is functioning fine, then that plant is prolific; but if shredder was not effective, then that plant is also inoperative. Under these conditions, it could be critical to be capable of monitoring the situation of that shredder machine and also that shredder mill. Two types of monitoring are there that could be supportive – one is the online monitor of efficiency (and power utilization), and situation monitoring of that apparatus itself. The conventional way for conditioning monitoring has always been to use the handheld shuddering analyzers, along with the facts being taken only once or two times a month. Hence, the disadvantage of this way is that it never detects any trouble that develops quickly, and the value of facts taken along with these types of analyzers always tends to be reliant on the procedure conditions. This kind of provision gives knowledge about the machine vibrations only; and it also is hard to show a relationship between the vibrations and the existing service situations. An important shredding plant of California (Simsmetals’ Redwood plant) used a Motornostix internet supported online situation monitor system for fitting their Alstom machine & Texas situated shredder mill (Soares, 2008). This Motornostix System uses a data logger which is known as Canary unit. These Canary units are in the vicinity network of any PC, which act as a link to the web or Internet. The facts collected by this Canary are used to be hosted on the fundamental database. From there it could be used to serve the users through a simple internet browser edge. Motornostix also has a primary database in a place called Cincinnati which does stores a bulk of data from its customers all the way from the USA, United Kingdom & Australia. Because of the tough site conditions, that includes usual bulldozing of entire area around the shredder plant, so it was resolute to never utilize a cable system to attach the Canary division to that bridge PC; but instead of it, a wireless system, based on the 2.4GHz frequency spread spectrum two-way radio, and also running a Motornostix protocol. It’s also being used to link the Canary part to any PC in a office building that is about a 100 yards away. This simplified the system installation to a large extent and therefore the net time taken was only 4 days. A snapshot of that system can be shown as under: Fig. 1: This figure shows the heart of this plant which we have discussed above. It has been shown in the open situation, while its maintenance. The shaft of this motor is very clearly visible. Temperature and vibration Sensors were mounted on both sides of that shaft. This is fairly comprehensive system apart from the shredder system and it controls a transformer for a 4000HP machine. Depending upon your design and eventual arrangement, there might be any additional various conveyors & special requirements you shall have to supply during concluding installation. The Shredder Machine Main Components: A Completely reconstructed Metso Texas 80104 Auto Shredder Mill having new liner grates and plates. Base RELINED. Middle section constructed from a NEW Front Wall Weldment by Riverside Engineering & RELINED. Topmost sections RELINED with the help of eject door. Hood RELINED. Undermill made Vibration Springs. Disk Rotor & bearings that are about 80% good & also a good SPARE ROTOR SHAFT & BEARINGS. Double Hydraulic Fed Rollers having a Hagglund Drive & a SPARE LOWER FEED ROLLER. Complete Hydraulic mechanism for Mill. Bearings lube section by mill. NEW United states Shredder Cat Tracks Infeed conveyor. REBUILT BEST, Inc Undermill Oscillator 76" x 16.2'. 1st Transfer Conveyor REBUILT. Dual Magnet Stands having Stearns 48" x 72" magnets, a Vibrator & 2 USED SPARE MAGNETS. 2 additionally utilized conveyors for trash and ASR. REBUILT Trommel having NEW screen. 1 NEW Unites States Shredder, 4 man preference conveyor 48" x 30' having four drop bins, walkways & two set of the stairs. 1 NEW United States Shredder Ferrous Radial Stacking Conveyor 48" x 70'. The Non-ferrous Equipments: 1 Osborne Eddy Current Separator - very good condition. 1 SGM Eddy Current Separator - good condition. 1 very good already used fines conveyor. 1 NEW SGM 60" Fines Line DSRP dirt separator. ! NEW SGM VIS Eddy Current System. with High Frequency. 1 NEW SGM DOUBLE Controller. 1 NEW SGM 60" Shaker Table. Motors and controls: 2500 HP Alstom Shredder Motor, which should have been recently serviced & inspected 2500 KiloVoltAmpere Transformer for 2500 Horse Power Motor. Liquified Rheostat for Alstom Motor. Starter switch for Alstom Motor. Universal Driveshaft and Coupling for Alstom Motor. 4000 Horsepower Toshiba Shredder Motor 4160Volts 480 Ampere rewind around 2004 to following: Rotor rewind to Category F 155 degrees Temperature Rise. Stator rewind to Category H 180 degrees Temperature Rise. Drive Shaft and Coupling for the Toshiba New REBUILT. Digitally Drive Systematic Liquefied Rheostat for Toshiba Motor. General Electrical 12,500 Volts Major DC for Toshiba Motors. Westinghouse 4160 V Disconnect device or Switch Gear for the Toshiba Motors. Capacitor 12,500/4160 Volts for the Toshiba Motors. Westinghouse 1200 Ampere Motor Starter device for the Toshiba Motors. Spare Wear and tear Parts: This type of Shredder approximately has 200,000 lbs of fresh castings & wear components, Grates & Liners Hammers etc. and also many other types of duplicate portions in the list. This Motornostix machine has proven itself of having considerable advantages to owners of these plants, as a management tool also & also as a situation assessment scheme. One major issue for these type of plants being that, it runs mostly at night. Due to this very large amount of power is consumed in California and hence cost also increases. This plant is made to operate during the night with the help of any skeleton staff, & therefore it becomes difficult for the management to build up an exact picture of plant’s output. Similarly, all those problems that occur during night are removed in the daytime by the help of a protection crew. Question 2: Failure Modes Analysis for the Shredder Machine This shredder mill machine is the critical machine. These plants classify the machinery according to the given guidelines. Machine Criticality meanings or Definitions A. High Criticality –Those Machines whose working cannot be broken up & upon which the entire production systems relies. B. Critical – Those Machines that are a key to meet production limits & also its working can’t be stopped during a manufacture schedule. Machines might be categorized as being critical if they follow the following conditions: 1. Repairing time is measured intolerable by production. ii. Lengthy lead timings subsist for spares. C. Non-Criticality - Those Machines that could be shut down while repairing. The Machines will be called non critical if: 1. They have the backup system that allows changes during the production. ii. The fixing or replacement duration will not influence the production & spare portions and laborers will be available always only if any repairs or replacements were required. Complicated systems generally have set objective availability. Another way to attain the objective is to amplify the reliabilities of all these subsystems. Though, guaranteeing higher dependability often incurs increase in price. One other solution can be to reschedule the Preventions. Our proposed method maps permits contrast between dissimilar accessibility development procedures and outline analysis in language of price, a widely used method of risk. Lifetime Price -Based FMEA could also offer appropriate Comparison between the conflicting designs of different subsystems (McDermott, 2008). This case study presented in the paper measured only the presently used magnet tools. The projected method may not merely extrapolate to latest, new and unproven tools, because observed or expert information might be not available. Thus, upcoming investigation lies in expecting ambiguity factors like detection time, frequency, fixing time & delay time) and using accessible component facts, and also extrapolating them till superior subsystem standards. Hybrid application of experimental and logical facts will present important new challenges. Table No. 2. Showing Run Tim period of Water Cooled Electromagnets Figure No. 2: Simulation showing Labor & Material by Monte Carlo Table 3: Predicted Life Cycle Failure Cost Table 4: Top Failure Price The respective motor-generator machine sets supply the power to a controlled-rod drive system. These generators are being driven using 50 horse power motors that are mostly synchronous machine motors producing 438 kVA power. Also maintaining a stable load on these generators, a big flywheel of around 1500 lbs used between the generator and motor is used. For example: Brown, 2007 Figure no. 1. Showing Spectrum Comparison – big Increase in the entire Uppermost Frequency Range in (Brown, 2007) Figure No. 2. Showing Spectrum Comparison – Increases to 120 Hz frequency (Brown, 2007) Question 3: Vibration Based Condition Monitoring System This Motornostix software, although being mainly designed for situation monitoring, also includes many number of the supervision tools which are very helpful in cases similar to this. An example for the exercise of these types of tools has been shown in the Figure 2 given below. This figure below shows 2 graphs giving motor performance across a 24 hours period.     Figure No.2: The Graphs above show speed (top) & current consumption (down) of this shredder motor machine for about over 24-hour time period, with a brink analysis done on the set of facts. In the above graph, the threshold is set slightly over the set no-load (ampere) current of the machine. The above shown are the real screenshots taken from the Motornostix software. Using any of the threshold tools in this software, one can also see that this motor has been running for 47.8% approximately of the time period, which only roughly corresponds to the most likely plant uptime that is 50%. But however, if anyone performs the similar examination of the current, & we set threshold to 275Ampere (that is also the given no-load set current of this shredder system), so we can also see easily that the runtime measured is 40.6 % approximately of the Time period. Saying it in any other way, this system was reaching its idealism for almost 7% of the net time period or approximately 15% of the time taken actually while running. The system would have been idling under the no-load situation –that is no input was being given to the shredder. Besides providing this information regarding the performance of the system, it also has the classiest sets of situation analysis kit available. Like for example, this machine is capable of performing the spectral study of these machine vibrations, with the spectral information being sampled in accordance with the predetermined situations. In case of these shredder motors, it was being decided to section vibration information when they are idling into the no-load condition, because it was thought that this will be giving the most clear vibration signals (Silva, 2007). The useful signals are swamped when the random signals are very high while the, metal is being crushed by the shredder. This spectral data received exposed that this drive end bearings of the motors was broken, even though not up to a worrying degree; a suggestion was given to the engineers of this plant for using this software to observe the progressive decline of the machine’s bearing. The damage of the bearing shown above is not at all less by any amount with the 3 sets of information, that is the primary spectrum, the Hilbert Transform or the demodulated spectrum, and also in cepstrum (the Fast Fourier Transform of the logarithm of this spectrum). The 1st of this is as shown in the Figure 3 below. Figure 3: Shown above is the Vibration spectrum Graph of the drive side of this shredder motor machine. One can see the major peaks in this spectrum graph at the bearings fault frequencies, mainly the outermost and innermost race frequencies: 82 Hz & 105 Hz. A secondary kind of monitoring has been shown in Figure No. 4, which is showing the vibrations of these shredder mill machine bearings which smear closest to these motors. This diagram shows shuddering for 4 days or shifts overnight. It could be seen also that during the 4th shift (12th July) the vibrations have unexpectedly increased considerably. Figure 4: The vibrations amplitude (root mean square) of the onboard bearings of these shredder mill machines, shown above for 4 shifts. During the 4th shift, the vibrations unexpectedly increase. The reason of this amplification could be understood by studying the spectrum graph, or frequency of the vibrations. This Motornostix system quantizes vibration when the motor is reaching its idealism before this mill starts giving out crumb; spectral examine times periods are symbolised by the triangles in red colour in the given figure. Figure No. five shows the comparison between the vibrations spectrum for these bearings that were taken on 11th of July and 12th of July (time periods shown by the 2 rightmost triangles of Figure 4). Figure No. 5: The Comparison between vibrations of the onboard bearings made on 11th of July (the green trace) &12th of July (the blue outline). It is also clear from the graph the vibrations at frequency b8.6 Hz shows a large increase which is also the running motor’s speed. This endangers the balance conditions of the mill. In Figure No. 5, we observe that the chief vibration peaks are at Frequency 8.6 Hz that is also the running pace of these motors. The occurrence of this tip symbolises a mechanical out of the balance situation; the dimensions of this peak symbolises that it should be taken into considerations, and also the rise from 1st day to next day suggest or symbolises that the circumstances are declining. Using the facts given by this Motornostix machine system, also the engineers of the plant were alerted timely about the discrepancy state, thus were easily able to correct the situation of imbalance by opening this hammer mill. Figures 3 to 5 are real screenshots taken from this Motornostix software, and delivered to the Internet. The customer is capable of selecting and modifying the images, using the Internet Explorer just as a software interface. Question 4: Estimated Cost and Implications Fig: The complete journey to excellence in operations by using situation monitoring Saving cost with Condition Monitoring To determine the savings in the cost without making many efforts, the plant estimated each inspection to have fast savings calculations that saved the time period used in doing that. Like for an e.g. a coupling which found to be in a bad situation is expected to have taken about two hrs of downtime, which is an unintended job for repairs. This calculation will look as follows: A: Cost: If the coupling brakes without giving any warning: Downtime * Price of Total Downtime/hr + Direct repairs cost (unexpected & Unscheduled) + Net Potential compensation B: Real cost of repairs: Downtime (if there are any – it should be predetermined in planned shutdown) * Price of Downtime/hr + straight repairs cost (scheduled & planned) + Damages (= 0) A- B = price evasion The price avoidance computation was completed by operation and repairs in the every day planning and arrangement meeting. The outcome was a price avoidance of about $100,000 in a time of seven months. Implications for situation Monitoring Equipment It is expected that the tendency of integration of situation Monitoring hard wares and soft wares with the other business system will enforce agreement with the industry-wide principles. While these principles are in this place for some time only, the compliance with such standards has been restricted and been grudged apparently by the producers. As we know that the marketplace for Process organized hardware & software is much big than that of situation Monitoring hardware & software, I might envisage that after the next decade, we will be seeing either of the following two options: Process control tools vendors inventing their own situation Monitoring hardware or software capabilities, or Procedure control equipment vendor acquiring the present players in this Conditions Monitoring equipment marketplace. At present, none of the chief vendors have a convincing ability in this field. Only the first vendor who has the potential to develop strong, dependable "expert" software with base on the open principles has the prospective to grow important market share. The following reasons are expected to escort to noteworthy decrease in the requirement for "conventional" condition monitoring agreement services: Increasing incorporation of Condition Monitoring hard wares and soft wares with the Process Control hard wares and soft wares and also CMMS software Increasingly complicated "expert" software permitting less trained personnel to carry out "first pass" situation assessment A decrease in the price of Condition Monitoring expertise allowing lesser organizations to perform cost-effectively the given condition monitoring activity. Reasonable against this were the following reasons that are probable to guide to an enlarged demand for the Condition or circumstance Monitoring services: An uplift in the count of tools items being controlled or monitored, as it then becomes extra cost-effective. Demands for growing complexity in the use of situation Monitoring technology, with a meticulous focus on the application of the technology or tactics in a way that maximizes or optimizes the business profits from the technology (Shahbazian, 2005). The chief implication of this on the Conditions Monitoring contractor is that: There are expected to have less no of "hands on" data set. There shall be less, yet more complicated data study, often using figures that have been collected direct on-site and then also transmitting electronically towards the contractor for study. Conditions monitoring contractors shall also need to accept a "mentor" mindset, instead of a conventional contractor mindset, in case they want to endure. In particular, the contractors need to recognize their customer’s business circumstance and also their manufacture procedures, and thinking in provisions of all those ways using which they could increase the market value of their customers business instead of using technology betterment issues as the prime consideration. For all the organizations that are using situation monitoring as a division of their repair policy mix, the following could be the expected implications for the beforehand mentioned trend: Situation Monitoring shall be regarded less & less as the "black art" demanding specialists to execute routine information collection and investigation, although these specialists will be still required to execute more difficult or unusual analysis. Production operator will more and more utilize the Conditions Monitoring tactics to emphasize potential tools troubles - either by means of hand-held tools, or everlastingly installed monitor which is included with the Process Control system. There shall be a decreased focus on usage of the Conditions Monitoring tactics to forecast equipment breakdown, and an amplified focus on the usage of these technologies to advance the equipments and constituents’ lives, and also to improve tools performances. It shall become more and more cost-effective, and more and more strategically vital, to perform regular Conditions Monitoring, rather than being contracting out these services. Question 5: Critical Analysis The online web monitoring scheme fitted with these shredder plants offers improved plant presentation and also organization information .It also monitors remotely. It can also be used for identifying the non-optimal functioning practice, & machinery troubles that may be developing. Wireless interconnection between the information logger and the PC thoroughly simplifies the setting up process, and also the deliverance of information to users through the Internet signifies that the management will be completely informed about the status of the plant comfortably from their houses or offices (Bedell, 2005 ). References: Bedell, Paul (2005). Wireless crash course, 2, illustrated 2005. New York: McGraw-Hill Professional. 60-70. Cassidy, Anita (2005). A practical guide to information systems strategic planning. 2nd ed. Boston: CRC Press. 200-225. McDermott Robin E., Mikulak Raymond J., Beauregard Michael R (2008). The Basics of FMEA. 2nd ed. Chicago: CRC Press. 178-195. Shahbazian Elisa, Rogova Galina, Valin Pierre (2005). Data fusion for situation monitoring, incident detection, alert and response management,Volume 198. New York: IOS Press. 115-120. Silva Clarence W. De (2007). Vibration monitoring, testing, and instrumentation. London: CRC Press. 95-115. Soares Claire (2008). Gas turbines: a handbook of air, land, and sea applications. Germany: Butterworth-Heinemann. 151-185. Read More