Setpoint Rolling Element Bearing Support

Transcription

1 Instruction Setpoint Rolling Element Bearing Support Installation and Operations Manual Keep accessible for future reference

2 Trademarks and Copyrights All trademarks, service marks, and/or registered trademarks used in this document belong to BK Vibro America Inc., except as noted below: Bently Nevada, Velomitor, REBAM, and Keyphasor are marks of the General Electric Company in the United States and other countries. Microsoft, Excel, Windows, and Outlook and their respective designs are marks of Microsoft Corporation in the United States and other countries. Modbus is a mark of Schneider Automation in the United States and other countries. OSIsoft, the OSIsoft logo and logotype, Managed PI, OSIsoft Advanced Services, OSIsoft Cloud Services, OSIsoft Connected Services, PI ACE, PI Advanced Computing Engine, PI AF SDK, PI API, PI Asset Framework, PI Audit Viewer, PI Builder, PI Cloud Connect, PI Connectors, PI Vision, PI Data Archive, PI DataLink, PI DataLink Server, PI Developer's Club, PI Integrator for Business Analytics, PI Interfaces, PI JDBC driver, PI Manual Logger, PI Notifications, PI ODBC, PI OLEDB Enterprise, PI OLEDB Provider, PI OPC HDA Server, PI ProcessBook, PI SDK, PI Server, PI Square, PI System, PI System Access, PI Visualization Suite, PI Web API, PI WebParts, PI Web Services, RLINK and RtReports are all trademarks of OSIsoft, LLC. Trademarks used herein are the property of their respective owners. Data and specifications are subject to change without notice. Copyright 2018, BK Vibro America Inc. All rights to this technical documentation remain reserved. Any corporeal or incorporeal reproduction or dissemination of this technical documentation or making this document available to the public without prior written approval from BK Vibro America Inc shall be prohibited. This also applies to parts of this technical documentation. BK Vibro America Inc 2243 Park Place Suite A Minden, NV U.S.A. Phone: info@setpointvibration.com Brüel & Kjaer Vibro GmbH Leydhecker Str Darmstadt Germany Phone: Fax: info@bkvibro.com Hotline: Phone: support@bkvibro.com

3 Related Information Document Number S S S S Title Setpoint Machinery Protection System Operation Manual Setpoint Condition Monitoring System Operation Manual Setpoint Hazardous Installation Manual Setpoint Calibration Interval White Paper PI Vision 2017 Installation and Administration Guide Brüel & Kjaer Vibro July 2018 C /V01 Page 3 of 39

4 EN Content 1 Overview 5 2 REB Channel Types Enveloped Acceleration Channels REBAM Channel Setting the REBAM Channel Rotor Region Filter Setting the REBAM Channel Prime Spike Filter REB Acceleration Channel Early Warning Prime Spike Overall REB Acceleration (Slow) Tracking REB Acceleration Channel 11 3 Configuring Bearings in PI-AF Viewing/Creating/Importing the Bearing Database Changing the Bearing Database Defining Bearings in an Asset Using PI Builder to Set Bearing Types and Speed 19 4 Viewing Bearing Frequency Cursors in Setpoint CMS 22 5 SETPOINT REB Rules Support Loading Templates into PI-AF Assigning Analysis Templates to a Channel 25 6 PI Vision Interface Example Messages and Severity Reason codes Acknowledging Events 30 7 Editing Alarm Set Points 31 8 Appendix A: REB Rule Template Functionality Additional Rules Rotor Region Lubrication Failure Rule Configuration 37 Page 4 of 39 Brüel & Kjaer Vibro July 2018 C /V01

5 Brüel & Kjaer Vibro Instruction VC-8000 REB Tools Overview EN 1 Overview The SETPOINT System has various channel types, analysis rule sets, and diagnostic tools specifically designed for protection and condition monitoring of machines with rolling element bearings. Configuring a complete rolling element bearing system includes these steps. Each step provides more functionality. You can install any level of functionality you need. 1) Configure the SETPOINT VC-8000 rack channels with the appropriate channel types (basic machine protection) 2) Configure the bearings in PI-AF. The bearing information is required for bearing frequency cursors in SETPOINT CMS. (basic condition monitoring and diagnostics) 3) Choose the rule sets to apply to the channels in PI-AF. (automated machine analysis) 4) Configuring PI Vision. (Advanced HMI) 5) After the system has collected data for a time period suitable to establish baseline operation, it may be necessary to adjust the system set points. Brüel & Kjaer Vibro July 2018 C /V01 Page 5 of 39

6 EN 2 REB Channel Types Configure channels types following the instructions in the SETPOINT VC-8000 Operation and Maintenance manual S The SETPOINT UMM provides several channel types specifically designed for rolling element bearing machines summarized in the table below: Channel Type Enveloped Acceleration REBAM* REB Acceleration REB Acceleration (Slow) Tracking REB Acceleration Application Using an acceleration sensor input, the enveloped acceleration channel provides early warning of bearing related faults by demodulating the signal and monitoring the configured bearing fault frequencies. Machines with installed Bently Nevada high gain REBAM* proximity probes. Provides early warning by monitoring the demodulated amplitude while also providing protection against imminent failure by monitoring the overall and prime spike filtered regions in either acceleration or integrated to velocity. Provides an enhanced demodulated (peak stretched) waveform to CMS software for bearing fault frequency spectral analysis. Low speed machines. Similar to the standard REB Acceleration channel except the peak detector and rms detector have been set for lower frequency operation. Machines up to 4500 rpm. Collects the demodulated synchronous waveform and extracts bearing frequencies that track as the speed changes. *Rolling Element Bearing Activity Monitor. REBAM is a trademark of General Electric. This channel type in SETPOINT is designed to closely emulate the signal processing for a REBAM channel in Bently Nevada 7200 series, 9000 series, 3300 series, and 3500 series monitoring systems. It assumes the use of a high-gain eddy current proximity probe system with either 5X (1000 mv/mil) or 10X (2000 mv/mil) gain compared to a standard 200mV/mil API 670 system. This gain occurs in the transducer, not in the monitoring system. The probe observes micro-deflections of the bearing s outer race and the monitor filters this signal to three ranges of interest: direct (unfiltered), rotor region (centered around shaft running speed), and prime spike (centered around bearing defect frequencies). REBAM channels cannot be used with any other transducer type than the 1000 mv/mil or 2000 mv/mil models specified. For seismic transducers monitoring rolling element bearings, do not use a REBAM channel; instead, the Enveloped Acceleration channel type will often be most appropriate. Page 6 of 39 Brüel & Kjaer Vibro July 2018 C /V01

7 Brüel & Kjaer Vibro Instruction VC-8000 REB Tools REB Channel Types EN 2.1 Enveloped Acceleration Channels Enveloped acceleration is a commonly used measurement for determining the health of rolling element bearings. Enveloped acceleration may also be used for other machine faults where impact events occur at regular frequency intervals. Direct Filter Rectification and Enveloping Band-pass filter and Peak or RMS detection Band-pass filter and Peak or RMS detection Band-pass filter and Peak or RMS detection Band-pass filter and Peak or RMS detection Band-pass filter and Peak or RMS detection The first step of the enveloping signal processing is the Direct filter that separates the impact carrier frequencies from lower frequency rotor related components. While this filter is configurable, there are several commonly used frequency ranges: 5 Hz to 100 Hz 50 Hz to 1000 Hz 500 Hz to Hz 5,000 Hz to 25,000 Hz The lower frequency of each band should be set higher than highest frequency of interest. For a typical pump running at 1800 rpm, the 500 Hz to Hz range is appropriate. Lower speed machines will use lower ranges. Set the Direct filter from the Measurements Configuration View as shown: Set the Direct filter corners for Enveloped Acceleration. Brüel & Kjaer Vibro July 2018 C /V01 Page 7 of 39

8 EN After the Direct Filter, the UMM signal processing continues with rectification, enveloping and additional filtering to separate out the bands of interest. The UMM provides 5 band-pass measurements that default to rolling element bearing frequencies: IRBP: Inner Race Ball Pass Frequency ORBP: Outer Race Ball Pass Frequency Cage: Bearing Cage Frequency Ball Spin: The ball or element 1X spin frequency 2X Ball Spin: Twice the ball spin frequency These filters are fully configurable and can be renamed as appropriate for applications other than rolling element bearings. Configure these filter ranges similar to the Direct filter as shown earlier. Page 8 of 39 Brüel & Kjaer Vibro July 2018 C /V01

9 Brüel & Kjaer Vibro Instruction VC-8000 REB Tools REB Channel Types EN 2.2 REBAM Channel Bently Nevada developed high gain drivers for measuring the very small displacements seen with rolling element bearings. This displacement signal is band-pass filtered to extract overall, rotorrelated, and element spike related frequency content. The SETPOINT UMM supports a REBAM channel that performs these filters Setting the REBAM Channel Rotor Region Filter The Rotor Region low pass filter is typically set at 3X the machine speed. Convert to Hertz (Hz) by dividing the running speed by Setting the REBAM Channel Prime Spike Filter The Prime Spike filter low-pass filter is typically set near 1X the outer race ball pass frequency. The high-pass filter is typically set near 7X the outer race ball pass frequency. Most bearing manufacturers have on-line calculators for determining the bearing frequencies. These tools allow you to select your bearing model, enter the running speed, and will calculate the fault frequencies at that speed. Brüel & Kjaer Vibro July 2018 C /V01 Page 9 of 39

10 EN 2.3 REB Acceleration Channel The REB Acceleration Channel provides a wide range of machine protection from early warning signs to imminent failure as discussed in the following sections Early Warning High frequency acceleration signals can indicate developing faults such as caused by lubrication problems, static discharge problems, or bearing problems. Peak-stretching has been shown to enhance the ability to detect the peaks over standard enveloping techniques. The REB Acceleration channel provides a peak-stretch demodulated high frequency measurement. The UMM filters the acceleration signal to capture high frequency components, peak-stretches the peaks and measures the peak amplitude. Since lubrication and static discharge problems generally are not periodic and can occur over a wide frequency range, the high frequency demodulated measurement is wide-band filtered. In order to see specific periodic harmonics, the peak-stretched waveform is available in SETPOINT CMS for spectral analysis Prime Spike Once lubrication or other "fixable" items have been resolved, a bearing can operate for a long time without change in high frequency content. Eventually, the rolling elements passing over the flaw can peen out the flaw and actually reduce the high frequency content. For this reason, the High Frequency Measurement is not a good indicator of when the machine must be shut down and the bearing replaced. The bearing fault progression causes vibration content to move into the element passage (also called Prime Spike) region typically defined between 1 and 7 EPx (element pass frequency). This is filtered off as a separate region so that the rotor related faults do not swamp out the bearing related information. When bearings reach this point of failure, pump seal damage can occur quickly Overall Additional faults due to misalignment, unbalance, instability, etc will show up at frequencies 1/4 to 3X running speed. The overall measurement filters are fully configurable over the frequency range and can be configured as an overall measurement or filtered to the rotor related fault region depending on the user s methodology. Page 10 of 39 Brüel & Kjaer Vibro July 2018 C /V01

11 Brüel & Kjaer Vibro Instruction VC-8000 REB Tools REB Channel Types EN 2.4 REB Acceleration (Slow) The REB Acceleration (Slow) has been modified for use on machines with speeds below 600 rpm. Since the lower frequency filters and peak detector responses take longer to charge and discharge, the REB Acceleration (Slow) channel takes a longer time to settle and return to an OK state after powering on the rack or after a NOT OK event. 2.5 Tracking REB Acceleration Channel The Tracking REB Acceleration channel includes tracking filters that change with speed to follow the bearing frequencies along with standard measurements used for machine protection and condition monitoring. The Tracking REB Acceleration channel is recommended for: Variable speed machines where the maximum speed is under 4,500 rpm. Channels where the accelerometer is mounted on a single bearing (not for gearboxes where the accelerometer is measuring vibration from multiple bearings/shafts). Standard measurements include: Overall 1X Amplitude/Phase HF Demodulated Bias Tracking bearing frequency filters: 2X Ball Spin Ball Spin Cage IRBP ORBP In addition, the Tracking REB Acceleration channel returns a synchronously sampled peak-stretched waveform. This waveform changes the sample rate according to the speed to hold the resolution (in terms of orders of running speed) constant over speed changes. Brüel & Kjaer Vibro July 2018 C /V01 Page 11 of 39

12 EN 3 Configuring Bearings in PI-AF In order to plot bearing frequency cursors on the spectrums in SETPOINT CMS you need to specify which bearing types are in the machine and assign them a to a phase trigger or to a fixed speed value. This section describes how to build a bearing database and assign bearings to a machine. 3.1 Viewing/Creating/Importing the Bearing Database A bearing database is a list containing the fault frequencies for given bearing types. The frequencies are listed as ratios of the rotational speed. In most cases this will be the internal ring rotation speed. In cases where the outer ring of the bearing is rotating, it is the difference between the inner and outer ring rotational speeds. NOTE! The bearing database is not intended to be a comprehensive database where you search for your bearings from a list of many bearing types. Rather, this database is intended to only contain information on the bearings in your machines using information loaded from online bearing frequency calculators. The SETPOINT REB Database is stored as a table inside the PI-AF database. 2. Select the Rolling Element Bearing Table. 3. Select the Table tab. 1. Select Library. Page 12 of 39 Brüel & Kjaer Vibro July 2018 C /V01

13 Brüel & Kjaer Vibro Instruction VC-8000 REB Tools Configuring Bearings in PI-AF EN 3.2 Changing the Bearing Database You can add bearings directly in the table or you can export the table and edit it in Microsoft Excel. The easiest way to edit the data in Excel is to copy the data from the table and then paste it into Excel. You can paste the entire table or just the new entries. Brüel & Kjaer Vibro July 2018 C /V01 Page 13 of 39

14 EN Enter the bearing model or type in the Type column and the bearing frequencies in the appropriate columns. Note that the cage frequency is often referred to as FTF (fundamental train frequency). After editing, import the.csv file back into the VC-8000 setup software. IMPORTANT! Be sure to check in your bearing table changes. 3.3 Defining Bearings in an Asset In some cases the transducer may be mounted directly on the bearing and present vibration information only from that bearing. In other cases, as with a gearbox, the transducer may be measuring vibrations from multiple different bearings rotating at different speeds. The next step is to define the bearings and shaft speeds that correspond to the instrumented asset. This section shows how to manually add and define bearing. If you have many bearings to define it is easier to use the PI Builder tool in Microsoft Excel. See Section 3.2 for information on using PI Builder to define bearings. NOTE! If you have many bearings to define, the PI Builder tool in Microsoft Excel makes this easier. See Section 0 for information. Choose Elements. Navigate to the level in the heirarchy where you need to set the bearing type. Right click, select New, and New Child Element. In the example below we are defining the bearing type for the Outboard bearing on machine DemoREB: Page 14 of 39 Brüel & Kjaer Vibro July 2018 C /V01

15 Brüel & Kjaer Vibro Instruction VC-8000 REB Tools Configuring Bearings in PI-AF EN Select Setpoint Rolling Element Bearing from the list. Brüel & Kjaer Vibro July 2018 C /V01 Page 15 of 39

16 EN Set the bearing type Select the new bearing element and open the attributes tab. The attributes will show errors until you set the bearing type. Click on the Bearing Type value and type in a bearing name from the bearing database. Click Refresh. Page 16 of 39 Brüel & Kjaer Vibro July 2018 C /V01

17 Brüel & Kjaer Vibro Instruction VC-8000 REB Tools Configuring Bearings in PI-AF EN The bearing frequencies will show the ratios for the set bearing type Associating Speed For machines without a phase trigger, type in the normal operating speed under the speed value. Click Refresh. The bearing frequency attributes will update with the fault frequencies based on the set speed. If the machine has a phase trigger, select the speed attribute. Change the Data Reference to PI Point. Under Settings set the PI tag name. Brüel & Kjaer Vibro July 2018 C /V01 Page 17 of 39

18 EN The easiest way to get this tag name is to navigate in the hierarchy to the speed point, select the speed measurement, select the speed data attribute. The PI tag name will show in the settings on the right. Check in your changes. Page 18 of 39 Brüel & Kjaer Vibro July 2018 C /V01

19 Brüel & Kjaer Vibro Instruction VC-8000 REB Tools Configuring Bearings in PI-AF EN 3.4 Using PI Builder to Set Bearing Types and Speed This section describes how to set the bearing types and speed sources. It is assumed that the hierarchy of machines and bearings already exists. From the PI Builder tab in Excel, select Elements, then Find Elements Searching for the bearings using the template Setpoint Rolling Element Bearing. 1. Set the Template to Setpoint Rolling Element Bearing. Search field will fill in automatically. 2. Click Search. 3. Click OK. A dialog will open which allows you to select what information is put into the spreadsheet. Choose Bearing Type, Speed and Template as shown: Brüel & Kjaer Vibro July 2018 C /V01 Page 19 of 39

20 EN Select Bearing Type.and Speed Ratio, Speed Reference, and Speed Target. Bearing Type: Set to the bearing Name in the bearing database. Speed Ratio: Use when the speed for the given bearing differs from the speed transducer due to gearing. For example, an internal shaft within a gearbox is rotating at twice the input shaft speed. The speed tag is measuring the input shaft speed. This bearing is on the internal shaft so set the ratio to 2. Page 20 of 39 Brüel & Kjaer Vibro July 2018 C /V01

21 Brüel & Kjaer Vibro Instruction VC-8000 REB Tools Configuring Bearings in PI-AF EN Speed Reference: Set to the speed PI tag name. If no speed tag is assigned, the system will use the Speed Target as the fixed speed. Speed Target: Set to the fixed rotation speed for machines without a speed transducer. For a machine without a speed transducer, leave the Speed Reference at the original value (auto fills with computer IP and No Speed Reference text) and set the Speed Target to the normal operation speed. Publish your changes. PI-AF System Explorer shows the new bearing after clicking Refresh. Brüel & Kjaer Vibro July 2018 C /V01 Page 21 of 39

22 EN 4 Viewing Bearing Frequency Cursors in Setpoint CMS When there are bearings assigned to the asset for a channel, the CMS software will show the spectral values at the bearing frequencies. To enable the bearing cursors, check the Bearings checkbox under the Spectrum settings on the Plot tab. The bearing frequency cursors are shown on the plot and the cursor names and amplitudes are shown on the right. The demodulation process creates harmonics of the fundamental fault frequency. Use the harmonics cursors (refer to CMS manual S for more information on cursors). Page 22 of 39 Brüel & Kjaer Vibro July 2018 C /V01

23 Brüel & Kjaer Vibro Instruction VC-8000 REB Tools Viewing Bearing Frequency Cursors in Setpoint CMS EN Brüel & Kjaer Vibro July 2018 C /V01 Page 23 of 39

24 EN 5 SETPOINT REB Rules Support SETPOINT REB Rules use the PI-AF Analysis tools and are defined in PI-AF templates. Since the analysis functionality depends on the machine type and the sensors installed, there are different templates providing different levels of analysis. This section describes: 1. Loading the rule templates into PI-AF 2. Assigning the rule templates to the channels 3. Converting to new or different templates if new templates are loaded into an existing configuration. 5.1 Loading Templates into PI-AF To import a set of templates into PI-AF, open PI System Explorer and select Import from File from the File menu as shown below. The Import from File dialog will open. Enter the rule file path and name as shown. Page 24 of 39 Brüel & Kjaer Vibro July 2018 C /V01

25 Brüel & Kjaer Vibro Instruction VC-8000 REB Tools SETPOINT REB Rules Support EN NOTE! Template file names may change. There may be an installation order that the files must be imported. Refer to the readme.txt file provided with the rule set templates for further installation information. NOTE! If you have already assigned the rules templates to the points and you are importing updated templates, PI-AF will automatically update the points to use the newly imported templates. 5.2 Assigning Analysis Templates to a Channel The Setpoint-PI Adapter will automatically build the PI-AF hierarchy using the standard Setpoint channel templates. To enable the analysis rules, you will need to convert the channel templates in PI-AF to the analysis template. This procedure also applies if you need to change to a different analysis template. Brüel & Kjaer Vibro July 2018 C /V01 Page 25 of 39

26 EN To assign or change a rules template, right click the channel, Select Convert, Select Change Template Select the new template and click OK. Page 26 of 39 Brüel & Kjaer Vibro July 2018 C /V01

27 Brüel & Kjaer Vibro Instruction VC-8000 REB Tools PI Vision Interface Example EN 6 PI Vision Interface Example There are many ways to show the machine information using PI Vision. OSIsoft has many excellent videos on how to build PI Vision HMIs. This sections shows an example of how you can display REB machine information and results from the analysis. The picture below shows some typical HMI elements. Trend lines of REB Measurements Measurement Status Channel Status Links to Setpoint CMS Event Messages Event Acknowledgement Brüel & Kjaer Vibro July 2018 C /V01 Page 27 of 39

28 EN 6.1 Messages and Severity PI vision can present a message in the Event Name column when a rule event occurs. These are free form text that the user can change from PI-AF. The following picture shows how to change message text and event severity using PI System Explorer. 2) Templates and Element Templates 3) Select Setpoint.RuleSet.REB 4) Open Analysis Templates Tab 5) Select Bearing Faults 1) Select Library 6) Change the message text as shown in the Name column. 7) Select Severity from the drop list in the Severity column. Check in your changes. 6.2 Reason codes PI Vision has a selectable reason field. The Setpoint rule set includes a list of common machine problems that you can choose from. You can also add your own additional reasons. For any event, the default reason is listed as unknown until the fault has been verified. To set a reason code, click on the pencil in the reason column at the given event. The Reason Code Editor opens. At the top, it lists the rule result. In the example below the rule result was a Late Stage 2 Bearing Fault. After viewing the peak stretch spectrum the user confirms the fault is an Outer Race Ball Pass fault (ORBP) and selects that reason code. Page 28 of 39 Brüel & Kjaer Vibro July 2018 C /V01

29 Brüel & Kjaer Vibro Instruction VC-8000 REB Tools PI Vision Interface Example EN You can add or delete reason codes using PI System Explorer. 2) Select Enumeration Sets 3) Select REB Fault Reasons 4) Add or delete reasons 1) Select Library Check in your changes when completed. Brüel & Kjaer Vibro July 2018 C /V01 Page 29 of 39

30 EN 6.3 Acknowledging Events Click the Acknowledge button to acknowledge events. The event will be removed from the list after acknowledging if the condition is no longer true. If the machine is still in the event state, the event will continue to be shown but acknowledged. Page 30 of 39 Brüel & Kjaer Vibro July 2018 C /V01

31 Brüel & Kjaer Vibro Instruction VC-8000 REB Tools Editing Alarm Set Points EN 7 Editing Alarm Set Points This section describes how to adjust alarm levels across many machines after collecting baseline data. Rolling element bearing high frequency acceleration from failures is caused by excitation of the bearing resonances when the elements pass over a spall or crack. The amplitudes of these vibrations is dependent on the bearing damping and not strictly on the severity of the fault. This makes it difficult to assign a fixed good/bad alarm level that can be applied to all machines. For this reason, alarms are typically set as a percentage above a baseline value taken when the machine was in known good condition. To view edit the alarm set points, open the PI Builder tab, select Elements, Find Elements: Under Template, select Setpoint.RuleSet.REB. Click Search Click OK. Brüel & Kjaer Vibro July 2018 C /V01 Page 31 of 39

32 EN Expand From Template Setpoint.RuleSet.REB Check the Hi and HiHi attributes for High Frequency Demodulated, Prime Spike, Rotor Region, Temperature, and Speed. Click OK. Page 32 of 39 Brüel & Kjaer Vibro July 2018 C /V01

33 Brüel & Kjaer Vibro Instruction VC-8000 REB Tools Editing Alarm Set Points EN The Excel spreadsheet will now show all the rule set points and the formulas used to derive The default template uses a formula to automatically set the HiHi alarm to two times the Hi alarm set point. You can change this multiplier in the formula. Publish your changes. Brüel & Kjaer Vibro July 2018 C /V01 Page 33 of 39

34 EN 8 Appendix A: REB Rule Template Functionality The REB rule template functionality depends on the available sensor inputs from the machine. The following table lists how the functionality increases as more sensors are added: Acceleration Sensors Acceleration + Speed Acceleration + Bearing Temperature Acceleration + Speed + Bearing Temperature Functionality Asset Mode, High Frequency, Prime Spike, Rotor Region In addition to the acceleration sensor rules, when a phase trigger is available the rules derive the asset mode (machine state) from the speed rather than from acceleration levels. In addition to the acceleration sensor rules, added bearing temperature measurements allow the rules to be extended to differentiate between bearing lubrication faults and bearing wear. Combines all of the functionality listed above. The UMM REB Acceleration channel makes measurements over the first 3 zones listed in the following table. The Very High Frequency zone is not used since it typically provides too early of a warning for use in an online system. Frequency Band Zone 1: Rotor Region Zone 2: Bearing Defects (Prime Spike) Zone 3: Bearing Natural Resonance (High Frequency) Zone 4: Very High Frequency, (Spike Energy) Frequency Content Typically set to ¼ to 3 times the shaft rotation speed. Rotor related problems such as unbalance, misalignment, instability, etc show up in this region. Typically set to 1 to 7 times the outer race element passage frequency. Vibration in this zone increases as the bearing failure progresses. High frequency data resulting from bearing fault impacts exciting the natural resonant bearing frequency. Demodulation (enveloping or peak-stretch) techniques are applied to this data to determine if the vibration is originating in the bearings. Ultrasonic data at the very early start of bearing failure. The bearing may not show any visible defects at this point. Since this vibration content occurs well before the user would take action, this frequency zone is not used in the rule analysis. The REB rules track the bearing failures through the life of the bearing as it progresses from the early stages to the later stages of failure. The rules and recommended actions are shown in the following table. Rules are only evaluated when the machine is determined to be running in order to prevent false alarms when the machine is off. When a phase trigger is not available, the machine state is determined by comparing current vibration levels against a calculated minimum. When a phase trigger is assigned, the machine is determined to be operating when the speed exceeds a threshold value. Page 34 of 39 Brüel & Kjaer Vibro July 2018 C /V01

35 Brüel & Kjaer Vibro Instruction VC-8000 REB Tools Appendix A: REB Rule Template Functionality EN Stage Normal Operation Description High frequency and Prime Spike regions contain little vibration content. Rotor Region shows normal vibration levels at 1X, 2X and possibly other rotor related harmonics. Bearing Failure Stage 1 Event: No fault events. Very high frequency content starts to increase. Bearing Failure Stage 2 Event: No fault events. High frequency content at the bearing natural resonance frequency increase. Event: Early Stage 2 Bearing Fault Late Stage 2 Bearing Fault Severity: Information Severity: Warning Brüel & Kjaer Vibro July 2018 C /V01 Page 35 of 39

36 EN Bearing Failure Stage 3 (early) High frequency content at the bearing natural resonance frequency continues to increase. Content in the Prime Spike region begins to increase. Bearing Failure Stage 3 (late) Event: Early Stage 3 Bearing Fault Prime spike region continues to increase. Severity: Minor Bearing Failure Stage 4 Event: Late Stage 3 Bearing Fault Severity: Major The bearing is approaching end of life. The high frequency data may decrease or just show noise due to peening effect of the elements passing over the spall or crack. Vibration in the Prime Spike region increases significantly. Rotor region vibration content increases due to increased clearances caused by the degradation. Event: Early Stage 4 Bearing Fault Late Stage 4 Bearing Fault Severity: Major Severity: Critical 8.1 Additional Rules In addition to the rolling element bearing fault progression rules, the REB rule package also includes the rules listed in this section Rotor Region The rotor region alarm can detect elevated vibration levels caused by rotor related problems such as imbalance and misalignment Lubrication Failure Available only when temperature sensors are installed. A lubrication failure is flagged when high frequency data is present and the bearing temperature is elevated. Page 36 of 39 Brüel & Kjaer Vibro July 2018 C /V01

37 Brüel & Kjaer Vibro Instruction VC-8000 REB Tools Appendix A: REB Rule Template Functionality EN 8.2 Rule Configuration The rules default to industry standards and typical operating conditions. You can alter the configuration parameters for your specific machine. This section lists the configurable parameters and information on changing them. Speed Target Speed Target is used to set to minimum speed for variable speed machines or running speed for a synchronous machine. To change Speed Target using PI Builder select Elements, then Find Elements Search for the Setpoint.RuleSet.REB template and select Speed Target under Attribute Columns- >FromTemplate Setpoint.RuleSet.REB as shown below: Brüel & Kjaer Vibro July 2018 C /V01 Page 37 of 39

38 EN Hysteresis Hysteresis (or dead-band) is applied to the rules to prevent excessive events when the signals are hovering near the set point values. The hysteresis default is 8% of the alert set point which is suitable for most applications. If you are seeing the rules continuously ratcheting in and out of alarm, you can adjust the hysteresis using PI Builder by selecting the hysteresis attributes as shown below. The hysteresis value is expressed as a percentage of the alert set point. Page 38 of 39 Brüel & Kjaer Vibro July 2018 C /V01

39 Brüel & Kjaer Vibro Instruction VC-8000 REB Tools Appendix A: REB Rule Template Functionality EN Brüel & Kjaer Vibro July 2018 C /V01 Page 39 of 39