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ABSTRACT

This paper describes a network architecture for remote monitoring

and fault detection of critical rotating equipment. Holcim’s Sphinx
Monitoring System (SMS) is intended for equipment protection and
early prediction of machine defects. SMS is based on a server-client
model, where the server maintains a database of equipment
configurations and evaluates each target with a unique set of rules
that monitor the equipment’s function and its integrated components’
failure modes. Adaptive software algorithms monitor process and
operational changes to tune the analysis criteria for evaluating
vibration signals and detecting common machine faults. Network
structure, software algorithms and other aspects of the system are
further discussed and evaluated against samples of collected data,
generated analysis results and physical inspections’ outcomes.

INTRODUCTION

Since the rise of online condition monitoring and the continuous

development of sophisticated competitive systems, the challenge has
always been in how to select the most cost efficient system that best
suits the application, while seamlessly integrating within the existing
automation infrastructure and successfully satisfying the system’s
main purpose of equipment protection and fault diagnosis. This can
be quite a dilemma, especially when the online network is required to
cover a wide variety of special applications within the same facility.
Standardization of industrial solutions and procedures is typically of
utmost importance to global organizations. However, realistically
what governs the selection of the automation and SCADA system
utilized is usually the resources, technical support and other
competitive advantages available in each market. This introduces
another level of difficulty in selecting the optimum monitoring
system, as compatibility between the different online systems and
automation solutions vary greatly between suppliers.
Holcim’s in-house developed SMS was designed and implemented to
address the above concerns. Its modular design allows for
monitoring different applications effectively, while its open
architecture permits direct integration with multiple platforms. The
developed solution uses “off the shelf” hardware, to ensure
availability, robustness, reliability and full compliance with industrial
standards. Furthermore, custom-made software, which provides
seamless integration within Holcim’s different IT Infrastructures,
supplies all technical and analytical results required for monitoring
and diagnosing critical equipment condition.

SYSTEM OVERVIEW

The system is an intelligent condition monitoring system that

dynamically adapts to operational changes while utilizing vibration
spectrum and waveform analysis to track mechanical and electrical
defects. The network structure, represented in figure (1), shows how
raw data is periodically stored and continuously analyzed to extract
Key Performance Indicators (KPIs), which are archived in a database
for trending and correlation. Select KPIs and alarms are then
communicated to the Process Control System (PCS) and Technical
Information System (TIS) via OLE for Process Control (OPC), for
protection and condition monitoring purposes.
SYSTEM METHODOLOGY

The system architecture, employing the data flow symbolized in

figure (2), applies the following methodology:

1. Dynamic signals are acquired from sensors through data

acquisition devices installed on equipment.
2. Signals are routed to the central server for analysis.
3. Signals are processed to generate waveforms and spectrums from
accelerometers and torque sensors.
4. Server dynamically adjusts analysis criteria to adapt to operational
parameters.
5. Analysis algorithms continuously perform fault detection and
amplitude tracking for various mechanical and electrical defects.
6. Analysis KPIs are extracted from spectrums and waveforms.
7. KPIs are stored in a Citadel database and are exported to PCS and
TIS through OPC.

ANALYSIS CAPABILITIES

The system automatically analyzes vibration spectrums, torque

fluctuations, phase relations and waveforms to extract mechanical
and electrical defects. Based on the following equations and
relations, software algorithms are capable of detecting and tracking a
wide range of defects, including:

Bearing defects:

Belt defects:

Electrical motor defects:

Fan blades and pump vanes defects:

Gear-mesh defects:

PROGRAMMING SAMPLE

This sub-program, displayed in figure (3), detects user interaction

with the radar plot and determines which KPI the user clicked on.
The result is then forwarded to another sub-program that extracts
the database location of the KPI’s values and trends its historical
data. To do this, the program divides the plot into equal wedges,
then determines the coordinates of the click, subtracts them from
the coordinates of the center-point of the radar, and computes the
inverse tangent of this value. The value must be adjusted, based on
which quadrant of the polar plot the user clicked in (because, for
example, inverse tangent of 45° equals tangent of 225°). This
program is written in such a way that makes it dynamic and valid for
any size of radar axes (i.e. any number of monitored KPIs).

SAMPLES OF ANALYSIS RESULTS

Discussed below are three case studies, where analysis results from
the online monitoring system were verified using handheld vibration
monitoring equipment and visual inspections were carried out to
evaluate equipment condition.

1. Finish mill process fan

System results, presented in figure (4), displayed an alarm on the

fan inboard bearing and alerted for inspection. The spectrum
frequencies matched the Ball Pass Frequency Outer Race (BPFO) of
the fan inboard bearing. Furthermore, comparison with the offline
vibration system, displayed in figure (5), confirmed the findings.
Visual inspection of the bearing, pictures displayed in figure (6),
found a crack in the outer-race and prevented a catastrophic failure.
Fan bearing data:
Bearing designation: SKF 2222k
Turning speed: 441 rpm
Bearing frequencies at turning speed: BPFO=56.1 Hz, BPFI=76.2 Hz,
FTF=3.12 Hz, BSF=23.3 Hz
Analysis results:
Spectrum analysis showed harmonics of BPFO and automatically
allocated that to the bearing condition axis on the radar view.
Furthermore, the radar view pointed out that the bearing condition
fault amplitude (displayed in black) exceeded the set alarm limits
(displayed in red).

Offline vibration measurements:

Route vibration measurements showed low amplitude harmonics of
BPFO at 56.3 Hz in the spectrums cascade along with defined
impacts in the waveforms. Hence confirming the bad bearing
condition.

Inspection pictures:

2. Girth gear wear

System results, presented in figure (7), generated a gear-mesh

alarm and showed increased trend of pinion/girth gear-mesh defect.
Comparison with the offline vibration system, displayed in figure (8),
confirmed the condition and prompted for a visual examination.
Inspection discovered scuffing and high loading zones. Pictures
displayed in figure (9).
Gears data:
Gears information: Pinion = 26 teeth, Girth gear = 240 teeth
Pinion Turning speed: 28 rpm
Gear-mesh frequency at turning speed: 12.18 Hz
Analysis results:
Even though the girth gear turns at 3 rpms and generates little
vibration, the presence of multiple gear-mesh harmonics with low
amplitudes generated a gear-mesh alarm on the radar view.
Figure (7) System results view

Offline vibration measurements:

Route vibration measurements showed low amplitude harmonics of
Gear-mesh frequency at 12.18 Hz in the spectrums cascade. This
confirmed the existence of an abnormal condition in the gears.

Figure (8) Offline system measurements

Inspection pictures:
3. Kiln cooler fans

System findings, shown in figure (10), detected increased looseness

and rubbing signs on both inboard and outboard fan bearings of
multiple cooler fans. The spectrum frequencies matched harmonics
of the fan turning speed along with multiple harmonics of fractions of
turning speed. Again, comparison with the offline vibration system,
displayed in figure (11), confirmed the condition and prompted for a
visual examination. Inspection of the bearing confirmed clear signs of
rubbing and looseness on both the outer races of the bearings and
the housing inner races. Pictures attached in figure (12).
Fan bearing data:
Bearing designation: Dodge 22224E1 K
Turning speed: 1800 rpm
Analysis results:
Spectrum analysis revealed harmonics of turning speed (1x) along
with unsteady phase and classified that as looseness. Moreover, the
harmonics of fractions of turning speed (1.25x and 1.75x), were
identified as rubbing. The radar view shows looseness and rubbing
exceeding the alarm limits and some electrical motor defects within
alarm limits.
Figure (10) System results view

Offline vibration measurements:

Route vibration spectrums showed harmonics of turning speed at 30

Hz, harmonics of 37.5 Hz (1.25x) and harmonics of 52.5 Hz (1.75x)
in the spectrums cascade. The condition would have been hard to
diagnose without considering the cross phase measurements
conducted by the online system and required advanced vibration
knowledge to detect.
CONCLUSION

The system has proven to be of great benefit in multiple aspects.

Having a dedicated network, separate from the process control
system (PCS), allows for continuous streaming of raw data that is
invaluable for post processing and analysis. Unlike other systems
that extract features from raw data streams then only transmit those
features to the PCS for trending, the capability of analyzing raw data
can be instrumental in identifying root causes.
Furthermore, the automatic and adaptive analysis features
accurately identify faults and takes on the analyst’s job of manual
vibration analysis, which requires considerable technical knowledge
and experience. In the meantime, it eliminates the time and effort
required for data collection, which can be allocated towards other
condition monitoring activities. For plants with multiple critical
equipment, which require frequent monitoring and consistent
analysis, it is vital to have an automated solution that is reliable.
The self-adjusting functions adapt to operational changes and
process fluctuations effectively, which results in accurate diagnostics
and gives the system advantage over other systems that require
extra sensors to perform equally.
Nowadays it is becoming mandatory to install vibration protection
systems on critical equipment, while online condition monitoring
systems are still considered a luxury. However, combining protection
with advanced diagnostic capabilities in one system yields enormous
cost savings and improves overall reliability tremendously, therefore
making the choice of a hybrid system more feasible.
Moreover, as the system was developed in-house, it integrates
seamlessly with the different control systems utilized by the
company worldwide. Compared to available market solutions, while
the system is still under development to provide more elegant
displays and user interface functionality, it has demonstrated to be
more cost efficient, reliable and effective in equipment protection and
diagnostics.

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