Here are the conferences that will be presented at the 2023 CMVA Annual Technical Conference.
Computers in Vibration Analysis – The Past 50 Years and What’s Ahead.
Keynote Speaker October 12, 2023
Bernie Pringle , P.Eng., Primac Reliability Consultants Ltd.
Over the past 50 years, computers have changed from something that few people personally interacted with, or knew much about, to becoming a pervasive part of everyday life. This has also occurred in the field of vibration analysis. I’ll review some of the ideas, major challenges, accomplishments, and changes that I’ve experienced while applying and using computers in my work as a vibration analyst from the early 1970’s to present. Many vibration analysts have embarked on a similar journey at various points on this timeline, and we have all arrived here in 2023 with much talk, both positive and negative on the future. With the advent of things like Chat GPT and the application of artificial intelligence affecting all aspects of society, the impact in our world of machinery will certainly not be benign. What should we expect? How do we deal with this? And how do we remain relevant and valuable as vibration analysts and reliability engineers? Let’s take a look and do our best to prepare.
Machining chatter: new solutions for an old problem
Keynote Speaker October 13, 2023
Keivan Ahmadi, Ph.D., P.Eng, Associate Professor, University of Victoria
Self-excited vibrations during machining operations become unstable if the machining parameters are not selected appropriately. These unstable vibrations are known as chatter and can lead to critical damage to the tool, spindle, or workpiece. Predicting chatter-free machining parameters has occupied researchers for decades, but avoiding chatter is still a significant problem in designing productive machining processes. In this talk, I will review the physics underlying chatter vibrations and the common methods of designing chatter-free machining operations. I will then discuss the challenges of implementing those methods in industrial settings and new developments that address those challenges. The emphasis will be on topics studied in the Dynamics and Digital Manufacturing lab at UVic, including the modelling and measurement of process damping in machining, vibrations of industrial robots with milling end-effector, applications of Operational Modal Analysis in chatter modelling, and data-driven modelling of chatter. Successful industrial case studies will also be presented.
Ultra Low RPM Condition Monitoring – 3 Years Pre-warning Time
Ron Kittle, SPM Instrument
HD ENV is a novel approach to the task of detecting gear and bearing deterioration in very early stages. By combining low noise hardware design and patented algorithms for digital signal processing with a standard vibration transducer (accelerometer), it is possible to extract relevant gear and bearing information from a noisy environment with exceptional clarity. Historically, gear and bearing damage detection using standard velocity readings (i.e. overall velocity values) could – in the best of cases – reveal severe damages in very late stages, thus resulting in very limited planning horizons. At best, a trend of increased velocity RMS values could be used to avoid unplanned stops.
Adding spectrum analysis based on velocity readings could reveal gear and bearing damages earlier than in the very late stages, but it was still a rather crude tool. When vibration enveloping was introduced several decades ago, it became possible to detect damages in earlier stages than before, and it then became relevant to talk about realistic pre warning times. With vibration enveloping, it was possible to extract information coming from gears or bearings even if the transducer signal was dominated by low frequency content typically originating from unbalance forces.
HD Technology (HD = High Definition) was introduced for the first time in 2010, when the SPM HD method (Shock Pulse Method High Definition) was launched. One of the goals of SPM HD was to detect bearing and gear damages on applications running at low or ultra-low rotational speeds (from 60 down to below 1 RPM). At these low RPMs, traditional vibration technologies were difficult – in most cases even impossible – to use with success, while SPM HD produced meaningful and generally excellent results. Since then, a large number of successful application cases utilizing the SPM HD method, especially low RPM applications, have been documented.
How to financially justify investment in your PdM program
Arnaud Deziel-Richer, Spartakus-Laurentide Controls
The primary purpose of any predictive monitoring (PdM) program is simple: to prevent catastrophic failures. These failures have negative effects by impacting machine availability, reducing production, maintenance costs, and thus decreasing overall plant profitability. An efficient PdM program can help mitigate these issues, and quantifying the potential savings is an important part of this to help justify investment in tools, training, manpower, etc.
This presentation will show the approach Laurentide Controls uses to help their clients achieve a quantifiable business approach using online Spartakus software, all while helping optimize the efficiency of their program. A few technical examples of vibration cases, from route-based data collection, problem detection, signal analysis and reporting will also be presented.
Non-Contact Vibration Analysis of Rotating Equipment Assemblies Using Mobile Phone Camera’s and Slow-Motion Video Recording
Luis Sabido (Dr. Thierry Erbessd, author), Erbessd Instruments
Summary: High resolution mobile phones with slow-motion recording capability provide an amazing resource for reliability professionals. We’ve already seen slow-motion mobile phone camera’s used in place of strobe lights to visualize and identify common faults like broken keyway’s, material build up on fans and more.
In this case study we will explore and evaluate the effectiveness of utilizing mobile phone video recordings for vibration analysis of rotating equipment to identify common machine health faults that previously required the use of hard-wired sensor technology in a non-contact method video post processing method.
Several different examples will be used to clearly identify misalignment, imbalance, looseness, phase related issues, and more.
Learning Objective: Understand the power of mobile phone camera technology available to nearly every reliability professional as they already have the phone available as a tool.
• Understand how camera frame rate relates to fmax
• Understand how camera resolution impacts sample resolution for analysis
• Understand how lighting impacts post processing
• Best practices for mobile phone non-contact vibration analysis
Case study of a Power Turbine
Gary (Guangxing) Zhang, Bently Nevada, a Baker Hughes business
A power turbine had been experiencing vibration trips during normal operation. During the event, a one-half (1/2X) vibration component emerged in the spectrum. This usually a good indication of that a light rubbing may have been developed at a seal area. Data analysis helped understand its vibration behavior and locate the rubbing area. The understanding was rather helpful for maintenance and operation teams going forward.
Hydraulic Turbine- Generator: Return-to-Service Test Planning
Matthew Holmes, Acuren
As the world shifts from carbon based energy production so does the reliability focus on existing and new green technology. In the hydraulic energy production space, there is renewed focus on ISO and CEATI standards to establish balance quality and operating vibration amplitude limits. Additional stresses are placed on assets with expanding operation envelopes, requiring generators to operate anywhere from synchronous condensing to maximum load. This presentation will review experiences with creating a return-to-service test plan based on ISO 20816-5 (limits) and ISO-21940 (balance quality) for a full operating range. Experiences with mechanical and load dependent (electrical and thermal forces) balancing options for a full operating range will also be discussed.
Condition Monitoring of Deep Draft Vertical Centrifugal Pumps
Jesse LaPaire, New Brunswick Power
A presentation consisting of guidelines and suggestions for the condition monitoring of deep draft vertical centrifugal pumps, as well as two case studies:
Case Study 1: Reviewing the root cause and lessons learned behind a raw service cooling water pump which had shaft whipping resulting from loss of the suction bell end and its interference with the with impeller.
Case Study 2: Tracking the story (detection of fault to correction/overhaul) of a 395 RPM single stage 7.55 cubic meter/second centrifugal cooling water pump with an impeller rub at the end of its 40 foot shaft.
Modal Amplified : Revolutionizing FRF and Modal Analysis.
Charles Gagné, STCD inc.
Modal Amplified, is an innovative and exciting technology that combines the power of a high-speed camera with an impact hammer or shaker to revolutionize the process of Frequency Response Function (FRF) and modal analysis. This cutting-edge solution offers a rapid and effortless way to perform these critical analyses, saving valuable time and resources.
Traditionally, FRF and modal analysis have been complex and time-consuming procedures that require specialized equipment and expertise. However, Modal Amplified simplifies and expedites the process by leveraging the capabilities of a high-speed camera and the Motion amplification software capabilities.
The high-speed camera, equipped with advanced imaging capabilities, captures high-resolution images of the structure or object being analyzed. Simultaneously, the impact hammer is used to introduce an impulse excitation to the structure, generating a response that is recorded by the camera. This combination allows for the extraction of key frequency response data and modal parameters.
One of the primary advantages of Modal Amplified is its ability to provide quick and accurate results without the need to create a 3D model. The camera captures a vast amount of data within a short time, enabling a comprehensive analysis of the structure’s dynamic behavior. This efficient data acquisition process significantly reduces the time required for testing, allowing engineers to quickly identify potential issues or areas for improvement.
Moreover, the technology’s ease of use makes it accessible to a wide range of professionals, regardless of their level of expertise. The intuitive interface and automated features of Modal Amplified streamline the analysis workflow, eliminating the need for extensive training or specialized knowledge.
In conclusion, Modal Amplified presents a game-changing approach to FRF and modal analysis. By harnessing the capabilities of a high-speed camera and the powerful software suite, this technology enables engineers to obtain quick and accurate results, ultimately improving the efficiency and effectiveness of structural analysis across numerous industries.
The Power of Ultrasound
Matthew Firth, NB Power
This Technical Presentation will walk you through the development and implementation of a plant wide Ultrasonic Lubrication Program as well as using Ultrasound as an early bearing fault detection method and for overall energy trends. We will discuss the capabilities and limitations of the hardware and software, as well as the pros and cons of acoustic lubrication. We will learn how the data collected during a lubrication survey can be used to detect early bearing degradation with the extraction of an Ultrasound Frequency Spectrum and Time Wave Form from the collected data. The presentation will cover personal experiences from developing the acoustic lubrication program at my plant and will include short case studies from failures that were detected using ultrasound where other technologies were unsuccessful. Enjoy!
Reciprocating Compressor High Frame Vibration – Case Study
Alexandre Gauthier, Suncor Energy
This case study tells the story of a one-of-a-kind reciprocating compressor failure mode captured with a Prognost protection and condition monitoring system. The compressor tripped suddenly on a high crankcase vibration event without any leading indicator. A systematic analytical approach will be presented from the trip event that trigger the protection system, through a complete compressor vibration signature analysis and risk review that led to an adequate decision-making process. Plausible failure modes hypothesis will be presented based on compressor dynamic and load characteristics. A targeted scope of works based on data and fact will be presented. Mechanical inspection findings with analysis of primary component failure mechanism and secondary damage propagation will be reviewed. A failure mode timeline will be reconstructed based on sound mechanical engineering concepts and asset operation understanding. A final discussion on protection system effectiveness and optimization will be done to reduce the consequence on health & safety, environmental, regulatory and financial receptors on up coming issues. Asset reliability is a journey, we must learn from asset failures to improve system effectiveness and improve operational safety.
Vibration control of a piezoelectric cantilever smart beam by L1 adaptive control system
Ali Ebrahimi Tirtashi, UVic
In this project, the modeling and design of an L1 state feedback adaptive control system applied for vibration control of a smart piezoelectric Euler–Bernoulli cantilever beam is presented. For a Single-Input Single-Output (SISO) case by considering the first two dominant vibratory modes, the dynamics of the system are presented. Three Piezoelectric patches, two as actuators and the other as a sensor are bonded to the structure at the support of the beam and along the length of the beam. L1 adaptive control law, with time-varying parameters and in the presence of disturbance, is employed to suppress the vibration of the beam. The beam structure is modeled in the state space form using the concept of piezoelectric theory, the Euler–Bernoulli beam theory, and the Finite Element technique. The proposed controller is also compared with PID and LQR control systems.
Using Acoustic Imaging Defect Detection
Gilles Lanthier, SDT
Exploring the use of Acoustic Imaging to discover and evaluate leaks as well as electrical and mechanical defects.
Optimize asset reliability and reduce unplanned downtime with new wireless sensor technology
Francky Ramaroson, SKF
Reliability teams face unprecedented challenges today: escalating costs, limited budgets, supply chain disruption, changing workforce, data security, and technology shortcomings. Do vibration data collection routes take valuable time away from addressing these challenges in your operation? What if you could detect machine anomalies on a wider range of assets to improve reliability and reduce unplanned downtime? Learn how new wireless sensor technology saves time while providing insights to optimize asset reliability and achieve your performance goals.
Predictive Maintenance in the Digital World
Keith Berriman, Spartan Controls
Technology allows us to monitor our equipment in real time more effectively than before. Digital connectivity allows our data sources to be combined and analyzed to give earlier warning of developing faults. How do we determine what to measure, how to connect data streams and how to present this information to our operations to drive effective decision making? In this presentation we will discuss the foundations of this digital PdM integration and what companies are doing to collect, analyze and present data to improve operational effectiveness.
Testing for Resonance
Dora Orchard, Acuren
Structures and equipment exposed to mechanical vibrations as well as ambient vibration are susceptible to resonances. Predicting resonance or potential resonant amplification is a desirable thing to achieve for many reasons – Operation of equipment at or near resonance can result in catastrophic failure, reduced reliability and functionality. Knowing the natural frequency characteristics of equipment will assist in the successful design and /or modification and operation of mechanical components and structures. This presentation will explore what resonance is, conditions that lead to recommendations for performing this testing, and test methods with analysis you can perform.
Importance of Quality Data in Diagnostics with focus on ODS, modal, SDM and FEA
Chris Roberts, Acuren
A large producer of grain products was venturing into a capital project to replace a large number of drive motors and gearboxes on material moving elevators. The project involved a total redesign of the foundation, base and mounting methods. This case study was the result of the initial installation of the first unit. No issues with the previous design were known and they ran for more than a decade with only typical maintenance practices. Newer design was selected based on “ease of pre-assembly” and “lower cost”. During commissioning of the unit, elevated vibration was immediately observed at the turning speed of the drive motor. Several corrective actions from on-site maintenance personnel and the OEM were made with no effects noted. Advanced diagnostics was proposed with focus on ODS, modal, SDM and FEA to recommend a path forward to the client. During these assessments the client asked to minimize downtime and expedite results to ensure the capital project remained on schedule. The result was initially obtaining data during non-ideal conditions with not all equipment in the area shut down which yielded inconclusive data. The client needed to be convinced that the proper path forward to an engineered solution was to redo a portion of the diagnostic to confirm the “Why”. Once completed the results were confirmed, structural and design engineers were able modify the base plate as required and implement this design across all remaining asset locations.