Mining Science

Mining Science, vol. 23, 2016, 191−202 (previously Prace Naukowe Instytutu Gornictwa
Politechniki Wroclawskiej, ISSN 0370-0798 in polish)
ISSN 2300-9586
www.miningscience.pwr.edu.pl
previously 0370-0798

Received March 17, 2016; reviewed; accepted September 16, 2016

VIBRATION ANALYSIS OF ROTATING MACHINES

FOR AN OPTIMAL PREVENTIVE MAINTENANCE

Mounia TALEB1*, Rachid CHAIB2

1
Department of Mining Engineering, University of Tebessa, Tebessa,Algeria
2
Laboratory of Transport Engineering and Environment, Mentouri University-Constantine, Algeria.

Abstract: Face to the development and competition to competitiveness, which drives the search for
quality and above ail; cost reduction, maintenance has become one of the strategic functions in the com-
pany. One of the solutions incorporated in management systems is Conditional maintenance that has
proved successful; Reduce downtime, optimize manufacturing, ensure safety and profitability of produc-
tion. For this type of maintenance to be effective, precise and reliable measurements are required. Expe-
rience has shown that vibration analysis is the most widely used technique for reliable monitoring and
diagnosis. The objective of this work is the study carried out at the Elma Labiod cement plant, which has
adopted continuous monitoring in the hope of an optimal approach to conditional maintenance. We use
the analysis of global velocity and acceleration levels, spectral analysis and envelope analysis to detect
defects and anticipate degradations that can affect a mechanism and determine the probable causes of
these malfunctions.
In this context, the actual measurements were analyzed by vibratory indicator leading to detection of the
weak points causing a malfunction on the machine (rolling bearings), therefor an optimization of the
maintenance is realized by monitoring the degradation through on-line control system. The analysis of
these vibrations let the possibility to detect and locale the defective components once the fixed corre-
sponding threshold limit of vibration level has been reached.

Keywords: Surveillance, Cement, Vibration, Conditional Maintenance

INTRODUCTION

The implementation of a policy of conditional maintenance of rotating machines

by vibratory analysis is now widely practiced in factories all over the world (Vasselin
and Combet 2015).
_________
* Corresponding authors: [email protected] (T. Mounia).

doi: 10.5277/msc162316
192 M. TALEB, R. CHAIB

Many searchers have been interested in the field of maintenance and vibration.
Eugène Désiré EFAGA proposes a general strategy for organization and management
of maintenance based on experience feedback, which consists in representing a struc-
ture that integrates the duality of the study on organizational and technico-economic
aspect, makes it easier for decision-makers to make the right decisions (Eugene,
2004).
B. Iung, E. Levrat propose an approach that uses “odds” algorithme, based on op-
timal stop theory. The objective is to select, from all the planned production stoppag-
es, those which will be optimal, to develop a maintenance tasks keeping the predicted
product conditions (Iung and Levrat, 2007).
In his thesis D. Claire Breneur studied the case of combined gear and bearing de-
fects by experiments applied to a gear unit model, he showed that the spectrum and the
cepstrum of the acceleration signal envelope are a performant indicators (Breneur,
2002).
In a study carried out in Turkish ,authors have shown that vibrational analysis pre-
sents much advantage as a predictive technique of maintenance. They have diagnosed
an external ring defect of a ball bearing (Orhan and al,2006).
In NF EN 13306 standard maintenance is defined as: “the assembly Of all adminis-
trative and management technical actions during the life cycle of an asset, intended to
maintain or restore it in a state which in, it can perform a required function”
(Duchemin, 2006).
In a manufacturing process, a often strategic role is played by Rotating machines,
like a press in a paper mill or a turbine in a power plant, they are part of this equip-
ment that can not be Not be able to stop at any time (Zani, 2003 ).
It is not enough to be concerned with the consequences of a malfunction but also
with its cause which can be internal or external. Starting from an observation of an
abnormal noise in the draft fan of the raw mill of the Tébessa cement plant, signaling
an imminent dysfunction, we used vibratory analysis to highlight the problem of the
equipment. The latter has experienced a lot of damage at the level of the reducer: the
excessive increase in the overall level of the speed, exceeding the danger threshold,
which indicated the existence of a defect of fixing, loosening Bolts, bearing wear etc.
Several defects can be encountered on this equipment which can carry other damage to
the whole technological chain such as unbalance, misalignment, wear of gears, play,
cracks, lubrication problems. It must be installed in cement plants because of the na-
ture of the finished product.
To make a good diagnosis, monitoring equipment is set up. The concept of moni-
toring is based on changing the signature of the vibration. In this context, two forms of
preventive maintenance are distinguished, namely conditional maintenance and pre-
dictive maintenance. Therefore, monitoring a machine requires selecting a certain
number of indicators, measuring them either continuously (on-line monitoring) or
periodically (off-line monitoring) and monitoring their progress in the time. Any sig-
 Vibration analysis of rotating machines for an optimal preventive maintenance 193

nificant change in the value of an indicator must lead immediately to the application of
an adapted procedure (validation of the evolution, identification of the anomaly and its
seriousness, scheduling of corrective actions, emergency stop, Exploitation in degrad-
ed mode, etc.) (Boulenger and Pachaud, 2003).
Generally, vibration sensors such as accelerometers are used for vibration monitor-
ing. The measured parameters are displacement, velocity and acceleration (Bertrand,
2000).

CASE STUDY

In this study we are interested in the fan of the raw zone of the Elma Labiod ce-
ment production line located 35 km from the town of Tebessa located in the east of
Algeria (Figure 1).

Fig. 1. Geographical location of the Elmalabiod cement plant in Tébessa

Following an abnormal noise reported by employees, and in order to anticipate the

degradation that may affect a mechanism, detect defects at a more or less early stage,
avoid very expensive production stoppages due to unforeseen failures, Diagnosis was
carried out using vibratory analysis (spectral analysis, measurements of global
vibrational levels in speed , acceleration and envelope analysis). The application
of this approach allowed us, after analysis, to estimate the risks of failure. Particular
attention is paid to fan reducer, which represents one of the links forming the cement
production line, from limestone extraction to cement shipping (Figure 2).
194 M. TALEB, R. CHAIB

Fig .2 . The cement manufacturing process (www.westchinacement.com)

As mentioned above, this work consists of the monitoring of a fan control equip-
ment R1S07 of the raw zone of the Elmalabiod cement plant (Figure 3) consisting
essentially of a motor, a reducer and a ventilator.

a) b)
Fig. 3. a) Fan control equipment, b) a sensor control point near the Fan

MATERIALS AND METHODS

In this work, we are interested in monitoring rotating machinery while using vibra-
tion analysis. This maintenance mode in machinery vibration analysis can better man-
age failures, detecting defects at an early stage, before they become critical (Bertrand,
2000).
 Vibration analysis of rotating machines for an optimal preventive maintenance 195

Machine monitoring is not limited just to detect the presence of a defect, but it is
also necessary to be able to make a thorough diagnosis to locate precisely and quantify
its severity. Vibration analysis is a technique that allows this diagnosis (Knight ,2001).
For clarification, diagnosis by vibration analysis requires to study: the values of the
overall level of vibrations, the frequency content of signals using signal processing
sophisticated tools (spectrum, cepstrum, envelope analysis etc.) (Djebili, 2013).
Note that the main technical data are required for classification of the equipment,
and determining the alarm thresholds for the establishment of the vibration signature
fan (Belhour, 2008).
The vibration analysis equipment used in this study are:
– An analyzer collector: Portable called “movilog2” which presents a very ad-
vanced synthesis of research, especially in computer science and advanced electronics.
This type of hardware has great performance thanks to its connection to a computer
equipped with software called “Diva”(Figure 4).

Fig. 4. Continuous monitoring (Belhour,2008)

– An Accelerometer: They are sensors used to ensure the vibration readings of a

various measuring points.
– A Vibration Analysis Software DIVA: This software is designed especially for
conditional and predictive maintenance, for the processing of the signals emitted by
different types of vibrations.
After a tour round, we found that the problem lies in reducing levels of raw fan of
the cement chain of production, cement plant Elmalabiod Tebessa. For lack of compe-
tence and surveillance equipment, the maintenance department in collaboration with a
specialized maintenance company found it useful to adopt a monitoring equipment.
We configured eight measuring points to detect weaknesses generating when there is a
machine malfunction (Figure 5).
196 M. TALEB, R. CHAIB

Fig. 5. Block diagram of the fan dispositive

RESULTS AND DISCUSSION

MOTOR AND REDUCER

On the motor and the gearbox the measurements have shown that the overall vibra-
tory levels readings for acceleration and speed and bearing failure are acceptable. We
go to the bearings of the fan or the problem seems more interesting and requires care-
ful interest.

THE FAN BEARINGS

The measurements carried out in 2012 on these items are shown in Fig. 6 and 7.
The first measure discern an elevated readings levels overall acceleration on the
bearings. However, the speed readings overall vibration levels are acceptable, and the
failure factor tolerable ride.
 Vibration analysis of rotating machines for an optimal preventive maintenance 197

Fig. 6. Curve trend in overall levels developed 8RH (1st degree)

Fig.7. Curve trend in overall levels developed 8RH (2nd degree)

The second measurement highlight the evolution of the NG acceleration and the
default factor to a high threshold 7.56 g – 8.05def.. To better understand the phenom-
enon and have more information about the malfunction, we went to the spectral analy-
sis fig. 8.
198 M. TALEB, R. CHAIB

Fig. 8. Spectral analysis in September 2012

The spectral analysis show the existence of an unbalanced fan of 0.01 g to

10.96 Hz. This is stable and acceptable with an evolution of energy at high frequencies
(defective bearing). Then for more details on the behavior of these elements, we ap-
pealed to the envelope analysis, Fig. 9.

Fig. .9. Envelope Analysis September 2012

GLOBAL ANALYSIS

In 2013 further steps were performed on the same fan control equipment precisely
levels or was revealed the results shown in the figures 10, 11, 12 and 13.
Overall analysis showed a change in the overall vibration levels recorded in accel-
eration axially to a tolerable threshold. As against the overall vibration levels recorded
in speed and bearing failure factor remained stable at a qualifying threshold figure 10.
 Vibration analysis of rotating machines for an optimal preventive maintenance 199

Fig. 10. Curve NG trend of acceleration, speed and def to entry

SPECTRAL ANALYSIS

This analysis revealed high amplitude to the 3rd harmonic of the meshing frequen-
cy 2.43g 3x 64.6 HZ, sidebands (modulation) around the meshing frequency spaced
by the frequency rotation of the PV output shaft and input 10.93Hz GV 24,99Hz, and
changing amplitudes of the first harmonics of the rotational frequency GV Fig. 11.
According to our results, we note the existence of several harmonics which are in-
dicative of defects inducing shocks such forces, such as games or chipping on surfaces
of a bearing or the teeth of a gear. The number of these harmonics depends on the
"brutality" of the shock, so its brevity (Boulenger, 2006).

Fig. 11. Spectral Analysis September 2013

200 M. TALEB, R. CHAIB

FAN BEARINGS

The overall analysis of these elements show the stability of the overall vibration
levels recorded acceleration and speed with a default factor tolerable bearing, Fig 12.

Fig. 12. Curve trend of accelerating loose bearing NG

SPECTRAL ANALYSIS

This analysis showed an imbalance acceptable fan 0.007 g 11 to 11 HZ.

Fig. 13. Spectral analysis of floating bearing

The almost-time intervention prevented the gear unit from deteriorating due to the
failure of the rolling bearings, which would have caused the fan of the raw zone to
 Vibration analysis of rotating machines for an optimal preventive maintenance 201

stop, with serious economic consequences related to: Production, estimated at 1200 t /
d (1 billion centimes).

CONCLUSION RECOMMENDATIONS AND OUTLOOK PERSPECTIVES

Technical and industrial mastery of the production facilities based in particular on

the current maintenance of equipment and systems, and exceptional service that is
related to the end of their technical life. In its most general sense, maintenance is not
restricted to the corrective actions on equipment, such as repair or replacement, but it
aims to ensure that the machines are constantly able to fulfill the function expected
from them, in good conditions of security and profitability. These actions include in-
spections of fundamental equipment for a diagnosis on the state of the latter. Thus, it
is necessary that industry shall ensure that the operators of facilities and strategic ma-
chinery (on the economic and safety plan) implement policies adapted to the mainte-
nance of safety and security issues, including a focus on quality and competitiveness.
Now, in practice, facilities get older and market competitiveness becomes a key con-
cern of manufacturers. Therefore, it is essential that maintenance remains appropriate
to the important role it must play in preventing incidents and unplanned outages: de-
tect and correct defects before they endanger the facilities health or production and
security in business. Vibration analysis allows for files to know the past evolution of
the state of the machine and safe procedure to predict dates, intervening just before the
failure occurs and make the replacement wisely. By that mean we can improve ma-
chines tasks and get them to a level often exceeding the origin specifications. Thus,
the maintenance phase should ideally be reduced to operations of replacing, without
trial and error, the actual equipment down and make selective service: "The vibration
signal is the identity of the machine."
To address the problem, we recommend rinsing and replacement grease free bear-
ing (fan side). At the end of this work we recommend the following actions:
Inspection of the state of the gears;
– Verification of the process (adjustment of the valves);
– Program the alignment of the chain.

ACKNOWLEDGEMENTS

The work presented was conducted in the doctoral thesis framework, among other we thank all those
who contributed to the realization of this study
202 M. TALEB, R. CHAIB

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http://www.westchinacement.com/ Group structure & MANAGEMENT TEAM consulté le 14 /03/2017.