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V-Sensing Lab(A branch of Infrared Engineering & Consultants Ltd.)
V-Sensing Lab CdM Series - SpiderWebWireless Condition Monitoring IoT System for HVAC EquipmentInno Portal Application - Equipment Preventive Maintenance using Internet of Things(Wish List Ref. W-0192)Electrical and Mechanical Services Department (EMSD)
V-Sensing Lab
Project Background• V-Sensing Lab was pleased to apply EMSD Inno Portal program
“Equipment Preventive Maintenance using Internet of Things” (Wish Listref. W-0192) to provide online Condition Monitoring (CdM) and smartsensing system for HVAC equipment.
• Integration of Predictive Maintenance (PdM) strategy and the concept ofIndustrial Internet of Things (IIoT), machines’ health condition data willbe collected, analyzed by the online system and send the real-timecondition / warning signals via LoRa.
• Set up early-stage fault detection algorithm and alarm triggeringprogram based on the vast data collected: maintenance cost $$ plant's asset reliability
V-Sensing Lab
Predictive Maintenance• Vibration Condition Monitoring (VCM) a kind of machinery
Predictive Maintenance (PdM) technique
• Fault(s) abnormal noise, vibration, current usage, temperature
• VCM can identify machine fault(s) & severity by vibration frequenciesand levels respectively
• Complete monitoring solution by integratingmachine temperature, current amperage, shaftrotating speed or any other condition indicators
• Cost-effective Asset Reliability strategy
V-Sensing Lab
Monitoring Modules
Vibration• Tri-axial vibration
RPM• Measure shaft RPM by Hall Effect
Amperage• 3-simultaneous channels for
motor’s 3 phases
Temperature• Thermocouple: range of -210° to 1800° C• Contactless: -50° to 350° C
General Purpose Input• Displacement sensor• Pressure sensor• Lubrication condition sensor
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Benefits• Extend machine life
• Prevent unexpected machine failure / emergency shutdowns
• Prevent catastrophic damage / accidents
• Diagnose machine faults at early stage and predict time to failure
• Reduce unnecessary over-haul and maintenance costs
• Reduce machine outage downtime
• Energy Efficiency
• Reduce vibration-induced noise & nuisance
V-Sensing Lab
IoT System
• V-Sensing VCMonline Series SpiderWeb Wireless tri-axial system
• IoT system for long-term continuous condition monitoring
• Continuous monitoring the mechanicalcondition of the machines with smart onlinealarm system for abnormal findings
• Ideal plant Predictive Maintenance solution
V-Sensing Lab
Vibration Diagnosis
• Coupling misalignment
• Mass imbalance
• Roller element bearing fault
• Sleeve bearing problem
• Mechanical looseness
• Electrical line problem
• Gear problem
• Impeller problem
• Belt and pulley problem
• Structural issues
• Flow problems
And many more…
V-Sensing Lab
FAST FOURIER TRANSFORM
(FFT)
• Our Monitoring System diagnoses machine fault(s) by identifying thevibration frequencies (type of fault) and the corresponding levels (severity)
• With our qualified vibration experts, the recorded FFT spectra will becompared with our pre-set machine fault and bearing database forbaseline alarm setting and diagnosis
V-Sensing Lab
• V-Sensing VCMonline Series offers complete bearing databasecontaining over 30,000 bearings:
V-Sensing Lab
Example: Water-Cooled Centrifugal Chiller (Gear-driven)
Motor
Coupling
High-speed Gearbox Impeller
Cooling Fan
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• Typical faults of gear-driven centrifugal chillers:
V-Sensing Lab
V-Sensing Lab
Alarm System
• Alarm level & triggering setting from statistical or baseline data
• Individual alarm triggering by vibration, current, RPM, temperatureor other machine condition indicators
• Provide indication to the plant managementfor quick response prevent furthermachine damage or catastrophic accidents
• Alarm signals in text / code form to be sentto management and engineers via LoRa WAN
V-Sensing Lab
Trending• V-Sensing VCM program will trend the entire machine life cycle
Roller Bearing Fault
Severe Screw Lobe Wear
Stage 2 & 3Random Fault
Site / Online VCMPredictive Maintenance
Stage 1Infant Mortality
T&C
Stage 4Wear Out – Failure
InvestigationBall Bearing Fault
V-Sensing Lab
• Gear Mesh Problem
High Gear Mesh Frequency (GMF) +1x driver / driven RPM sidebands(depends on where the bad gear is)
Regular lubricating oil analysis isrecommended
GMF = No. of teeth x Shaft Speed
Driven Speed = Driver Speed x Driver Teeth / Driven teeth
*Figure from Mobius Institutehttps://www.mobiusinstitute.com
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Early Stage(5 – 10% bearing life remaining)
Mid Stage (Ball defect)(1 – 5% bearing life remaining)
Mid Stage (Outer Ring) Mid Stage (Inner Ring) Late Stage (severe)(Replace bearing ASAP)
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• Bearing Fault – Stage 3(Ball / Roller Damage)
Non-synchronous harmonics at Ball SpinFrequency (BSF) + Fundamental TrainFrequency (FTF)
Impact each time the damaged areacontacts the inner / outer race canbe observed from time waveform signal
Remaining bearing life: 1% - 5%
W a v e f o r m2 7 / 8 / 2 0 1 8 1 1 : 4 6 : 1 9
s e c s0 0 . 0 5 0 . 1 0 . 1 5 0 . 2 0 . 2 5 0 . 3 0 . 3 5 0 . 4 0 . 4 5 0 . 5
mm
/s
- 5 0
- 4 0
- 3 0
- 2 0
- 1 0
0
1 0
2 0
3 0
4 0
5 0O / A l l 1 0 . 5 1 m m / s R M S
T r u e p k - p k 8 1 . 4 5 m m / sC r e s t F a c t o r 3 . 8 7 4
2 7 / 8 / 2 0 1 8 1 1 : 4 6 : 1 9 O / A l l 1 0 . 5 1 m m / s R M S 1 4 8 5 R P M
*Figure from Mobius Institutehttps://www.mobiusinstitute.com
V-Sensing Lab
Specification - Vibration• Wireless tri-axial accelerometer + temperature sensor• Sampling rate: 25,600 Hz• 10 kHz Fmax• Max. 6,400 lines of resolution• Full waveform & spectrum data• Programmable internal RMS trigger
• Battery type: 3.6 V Li – TL-5935• Battery life: 2 – 4 years• Wireless Data transmission: 2.4 GHz BLE 5.0• IP67 – dust & water-proof• Operating temperature: -40°C – 85°C
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Specification - Amperage
• Wireless 3-phase current module• Sensor type: Non-invasive clamp type• Sensor range: 50 / 150 / 500 / 1000 A• 50 / 60 Hz up to 400 Hz• Accuracy: ±0.5 / ±1.5 / ±1 / ±1%
• Battery type: 3.6 V Li – TL-5935• Battery life: 5 – 9 years (4 – 6 collections per day)• Wireless Data transmission: 2.4 GHz BLE 5.0• IP67 – dust & water-proof• Operating temperature: -40°C – 85°C
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• Wireless RPM module• Sensor type: Hall Effect - Omnipolar• Sensor range: 0 – 200,000 RPM• Sensor gap: 1 – 15 mm• Magnet type: Neodymium
• Battery type: 3.6 V Li – TL-5935• Battery life: 5 – 9 years (4 – 6 collections per day)• Wireless Data transmission: 2.4 GHz BLE 5.0• IP67 – dust & water-proof• Operating temperature: -40°C – 85°C
Specification - RPM
V-Sensing Lab
• Wireless temperature module• Thermocouple type: K/J/N/R/S/T/E/B• Sensor range: -210°C - 1800°C• Sensor accuracy: 0.15%• Resolution: 0.25°C• Max. wire length: 25 m
• Battery type: 3.6 V Li – TL-5935• Battery life: 5 – 9 years (4 – 6 collections per day)• Wireless Data transmission: 2.4 GHz BLE 5.0• IP67 – dust & water-proof• Operating temperature: -40°C – 85°C
Specification - Temperature
V-Sensing Lab
• Wireless general purpose input module Shaft displacement Pressure
• Simultaneous 2-channel measurement• Input range: ±3 Volts / ±24 Volts• Amplitude range: 24 bits – 108 dB• Sampling rate: 44.1 kHz
• Battery type: 3.6 V Li – TL-5935• Battery life: 2 – 4 years• Wireless Data transmission: 2.4 GHz BLE 5.0• IP67 – dust & water-proof• Operating temperature: -40°C – 85°C
Lubrication Condition Speed
Specification – General Purpose Input
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Specification (cont’)
Weight: 100 grams
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Setup
• Vibration monitoring at the bearing locations of the machines inthree orthogonal directions (horizontal, vertical & axial):
• Vibration sensors shall be attached to the bearing housing by strongmagnet, adhesive or permanent stud mount
• Current amperage monitoring at the 3 phases of the motor currentinput by clamp meters
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• Example of wireless vibration sensor setup:
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Schematic DiagramMonitoring & Data Transmission Station(IP65 plastic enclosure (Dimensions: 320x240x110mm))
*BLE - Bluetooth Low-Energy 5.0(Connect max. 100 sensors per gateway)
LoRagateway(EMSD’s LoRa
infrastructure)
BLE
Chillers / Compressors
BLE
BLE
220V AC power
Wireless gateway
RS485 to LoRainterface
Data processor
LAN cable
RS485Wifi
routerWifi
LoRaWAN
Water Pumps
Air-Handling Units
BLE
Cooling Tower Fans
V-Sensing Lab
Consultancy Services
• Vibration data analysis by V-Sensing Lab’s Certified VibrationAnalyst* regularly
• Early-stage fault detection and diagnosis
• Review triggering alarm level(s) regularly
* V-Sensing Lab's vibration analysts are qualified inaccordance with ISO 18436-2:2014 "Condition monitoringand diagnostics of machines -- Requirements for training andcertification of personnel -- Part 2: Vibration conditionmonitoring and diagnostics"
V-Sensing Lab
ContactFor more information, please contact our NDT engineers:
Andrew YEUNG Email: [email protected] KO Email: [email protected]
V-Sensing Lab(A branch of Infrared Engineering & Consultants Limited)
Address: Suite 1603, 16/F, Chinachem Johnston Plaza,178 - 186 Johnston Road, Wanchai, Hong Kong
Tel: +852 2550 2330Fax: +852 2550 1179Website: V-Sensing.comEmail: [email protected]