Home

Diagnostic Rolling Element Analysis Module (DREAM)

1. New Only Select this option to display only new spectra from the Sentinel database that have not been processed by DREAM in the third list Another way you can process the all spectra stored in the Sentinel database and suitable for DREAM X History select this option to diagnose all previous spectra together with the selected one This can be valuable to review the defect development from measurement to measurement n this case much more time may be needed to process all the spectra In the Rotation Frequency input box enter the actual rotation frequency during measurements At the bottom of the dialog box there are two buttons Click this button and the spectrum will be processed automatically and the results of diagnostics displayed in the Detailed Diagnostics ee dialog box comen Diagnose X Cancel Click this button to close this dialog box DREAM Fig 4 33 The De tailed Diagnostic dialog box with a list of defects and rec ommendations Chapter 4 Menu Description 4 25 When you click the Diagnose button the spectrum will be processed Detailed Diagnostics Revolution around outer race Honuniform radial tension of bearing Misalignment of outer race Wear of outer 80 x 802 Cavities on outer race 12 50 Wear of inner race Cavities on inner fear of balls or rollers Cavities spalling on rolling elements 14 702 Defe
2. File View Options Window Help ECT Print Preview Print NN Setup 117 110 O Date 3 0 Plot Section Copies the active window contents and puts it the Clipboard Besides you can immediately print the contents of the active window using the Print or Print Preview commands The graph will be stretched to the paper size and orientation of the default printer change these parameters use the Printer Setup command If you try to run more than one Spectra Display you will fail You must find Spectra Display yet opened close it and run again for the new selected node DREAM 3 7 REPORTING List of Bearings Points Configuration Measurement Setups Points To Be Measured Conditions Recommendations Chapter 3 Operating the DREAM Program 3 31 After diagnostics all the results are stored in the DREAM database and can be retrieved in several types of reports The commands of the Report menu issue reports for the selected node in the plant tree There are only two exceptions The first is the List of Bearings by Szatisticscommand that is made for all plants and does not depend on the selected node The second is History that can be made only for a selected measurement point When you select a node and issue a report all measurement points that are below this node in the tree hierarchy are included in the report This report presents all designations
3. All operations in DREAM can be made with a selected node in the plant tree For example if you selected a node and issued a report the report will be created for the whole branch below this node Besides the standard menu bar you can access several commands by the floating menu To access it click with the right mouse button Fig 2 16 Click the right mouse button to display the floating menu with the most common com mands Operator s Guide DREAM anywhere in the main window The commands from the floating menu will be executed for the selected node DREAM for Sentinel DataBase Measurement Point Spectra Repons Help 1 Calibration T 1 Balancing vite de Montr al m Configuration Ji Fitration Atwater setup Maintenance Jil D shumicificateurs Last Results Analysis Diagnose Jl pas Li 1 To navigate through the plant tree you can also use the arrow keys up down If the expanded plant tree is large you can go fast to the end or to the root of it by the Home End keys DREAM Chapter 3 Operating the DREAM Program 3 1 3 OPERATING THE DREAM PROGRAM 3 1 CONFIGURATION Fig 3 1 Main window of the DREAM soft ware with the names of the plants config ured in the Sentinel database The DREAM program is used to provide the user of Sentinel the means for automatic diagnostics and condition prediction of rotating machinery The operation with DREAM ca
4. Axes 2 Axis First axis rotation frequency Hz Rotation frequency variation Maximum varaton 3 10 Fig 3 14 The Gear box Specification dialog box Note Operator s Guide DREAM If there are no gearbox types configured by you the list is empty and the gearbox scheme is absent You must choose the Gearbox Specification via clicking the New button Gearbox Specification Ie 0 1 Axes Ass Teeth 1 2 221 2 8 3 z i J 1m zn Moving through input boxes in turn by striking the Tab key or mouse button clicking you must name the gearbox type that you are setting at the Type box type axes number in the Axes box and teeth number in the Teeth boxes column Each gear has its own combined number The first figure indicates the number of the axis on which the gear is placed the second figure indicates the number of the axis on which the connecting gear is placed For example Z12 is the gear placed on the first axis input shaft and connecting to a gear placed on the second axis To complete the gearbox specification click the OK button You will be back to the gearbox configuration window To change or delete the gearbox type use relative buttons Change Delete If the certain gearbox type used yet for the several measurement points you can not delete that type at once First you have to know all the measurement point with that type configu
5. Install Device Driver Default Recommender Fig 2 11 The dialog of the Security program Install Device Driver Using Setting Specified by the Far amp d anced Information on Device Remove Software Security s Device Driver Installed an your DREAM Fig 2 12 A program group is created by the Setup program Fig 2 13 The main window of the DREAM software before opening the database Chapter 2 Starting Up 2 7 The driver for the hardware protection key to work with Windows will be installed onto your computer After the installation of DREAM for Sentinel the Setup program will automatically create a program group DREAM for Sentinel in the Program Manager and add there two items DREAM and Report Preview You can easily drag this items with a mouse to any program group you prefer 21 File Options Window Help File Manager Control Panel e E ES Ae Viewer MS DOS Windows Prompt Setup PIF Editar Print Manager Preview To ensure that DREAM software was installed successfully attach the electronic key to the parallel port and try to start DREAM by double clicking its icon You should see the DREAM for Sentinel window with the menu bar DREAM for Sentinel L d 2 8 Operator s Guide DREAM C ATTENTION The DREAM application software runs only when it finds the electronic protection key The e
6. spectrum includes PATINE Based on recommendations NOT IDENTIFIED DEFECT 80 Severe with the reasons for We pearing Based on them all defects and WEAR OF OUTER RACE 80 Severe Probability 80 their symptoms to CAVITIES SPALLINGS ON ROLLING ELEMENTS 1 4 Severe Probability 7094 gether with the pos DETECTED DEFECTS sible warnings and WEAR OF OUTER RACE 80 Severe Probability 80 Diagnostic symptoms in the envelope spectrum comments Warning Diagnostics is based on the harmonics of the rotation speed only they can occur due to the defects of other units If the electric mains frequency in your area is 60 Hz the diagnostic symptoms may be caused by the electromagnetic interference 5 91 Hz 8096 Frot 11 82 Hz 189 2Frot 17 73 Hz 28 3Frot 23 64 Hz 199 4Frot 29 57 Hz 896 bFrot 35 41 Hz 896 bFrot 41 37 Hz 122 Frot 2Frol 2Fc 53 18 Hz 17 S Frot 59 11 Hz 139 10 65 05 Hz 820 11 3Frol 2Fc RA AR Hz IA ThFErnt AFrnl 2Fr DREAM 3 6 ANALYSIS Fig 3 35 The main window of PLOT program that is used for the analysis and diagnostics of spectra within DREAM soft ware Chapter 3 Operating the DREAM Program 3 27 Besides data processing in automatic mode described above DREAM has detailed analysis mode for all spectra stored in the database To access it choose point in the plant tree in DREAM and choose the Analysis command from the Meas
7. tion window you can see trends on the spectra components at the cursor position Operator s Guide DREAM Synchronous to the movement of the cursor in the Analysis window the section in the Section window changes the horizontal axis here represents the intervals between spectra measurements and the vertical axis amplitude of the spectra at the position of the cursor in the Analysis window and the cursor moves in the 3 D Plot window Spectra Display Measurement Point B File View Graphs Options Window Help jth M fee Se 345 0 Hz 102 95 c LL Dae 14 s 05 96 16 57 m 18 04 96 18 43 Besides normal cursor you can display two harmonic cursors One is called Harmonics and can contain both harmonics and sidebands another is called Harmonic Row and can contain only harmonics The number of harmonics in these cursors and number of side bands and modulation frequency for the Harmonics cursor are controlled by the Harmonicscommand from the Options menu To display harmonic cursors use corresponding commands from the View menu or click the following buttons on the speed bar to display Harmonics cursor to display Harmonic Row Buttons are used to move Harmonic cursor buttons are used to move Harmonic Row cursor DREAM Chapter 3 Operating the DREAM Program 3 29 Fig 3 37 The Har spectra Display Measurement Point Analysis monics c
8. 1996 rr 1 2 3 4 5 b n B 3 10 1l 15 1B 17 18 23 24 25 293 SU 31 In this dialog box you can select a date for which the report will be issued To select a date within current month just click it with the left mouse button To change a month and a year use the following controls advances one year Advances one month Goes one month backward Goes one year backward Applies changes and close this dialog box Disables changes and close this dialog box After your selection the Points To Be Measured report is displayed PrePrint meas qrp 10105 2 56 55 PM Mille de Montreal Filtration Atwater Deshumidificateurs PROCEDE4 De muere s s se Lm pues es o ee s s m m9 ree me 4 36 4 5 5 CONDITIONS Fig 4 45 The Mea surement Point Con ditions report Operator s Guide DREAM In the Meas Date column you can see the expiry date of the condition prediction If this point have not been measured previously a Not determined note will be presented in this column It is very important report that is used to plan measurements configured in DREAM measurement points that have not been measured or condition of which should be refined by a certain date are included in the list together with the measurement setup for each point This command displays the Measurement Point Conditions report PrePrint cond qrp Meas
9. Eu ERE Analysis TEC m ME E s o pen B 09 05 96 15 57 E 18 04 96 18 43 Narrow Cursor This places all in one line at the bottom is places all in one line at the bottom of the desktop the desktop the icons and windows are listed in the second part of the Window menu There are Date 3 d Plot Section Analysis If you select the window from the list of this menu it will become active This menu contains the single item About spectra Display Measurement Point Be Analysis File View Graphs Options Window EE ee About MEAE Information about the pragram Displays the copyright and version information for Windows Spectra Display Version 1 0 Copyright 1996 Inteltech Enterprises Inc Copyright 1996 VAST Inc All rights reserved DREAM 4 3 6 DELETE DATA Fig 4 3 The dialog box for the confirmation of the Delete Data com mand 4 4 THE SPECTRA MENU Fig 4 31 The Spec tra menu Diagnose Chapter 4 Menu Description 4 23 This command deletes the configuration data for the selected measurement point Then you can configure the measurement point once again and all the spectra stored in the Sentinel database may be proceeded by DREAM as new ones The command requires the confirmation and displays the corre sponding dialog box Q Delete ALL configuration data and diagnostics results for Measureme
10. gt gt Fig 4 8 The last section of the Measurement Point Configuration dialog box is used to set or confirm defect levels Chapter 4 Menu Description 4 7 warning that data have variations and during processing program has revised them to identify the defect The program generates the same warning if there is a mistake in the number of rolling elements in the limits dNrol An input box to enter the maximum value of variations in the input data for the Rotation Speed in 90 at which the program will still identify the type of the defect but will give a warning signal to the Operator Ifthe variations exceed the Max Variations value the program will detect the defect and its depth but will not identify the type of the defect In this case the type of the defect will be defined as a Not identified defect NID When such information it is recom mended to enter the Variations of about 2 3 and maximum variations not more than 1090 Click this button to disable changes and close this dialog Click this button to apply changes and go to the previous section of this dialog Click this button to apply changes and advance to the next section of this dialog Enter the above values and click the Nextbutton The program will automatically calculate the levels for severe defects and advance to the next section Measurement Point Configuration PP 1 Rev ol
11. 13 This command is used to enter the manual mode of diagnostics Despite DREAM is thought to be an automatic systems for diagnostics of different types of rotating equipment it has an advanced tools for an expert to deal with spectra A special Plot application is started by this command that provides an experi enced operator with graphic interface for diagnostics By this command the Spectra Display window appears Spectra Display Measurement Point B File View Graphs Options Window Help EE ERE Analysis OOOO A UY sewon some zi Li 100 18 04 96 18 43 ee ee j Here are presented dates of all envelope spectra measurements that are stored in the database of Sentinel and can be used for the diagnostics of the chosen in DREAM point The main window of the plot program contains the Analysis window where the spectra are displayed the Date that allows you to choose spectra for display and analysis the Section that displays the history of certain spectra component s development from measurement to measurement and 3 D Plot that displays the 3 d surface representation of the spectra development in the period from measurement to measurement Under the menu bar there is a speed bar with control buttons for controlling the cursors and operating the active window contents copying printing Their uses are as follows to display hide the Harmonics cursor The button correspond
12. Close Alt F4 0 100 200 300 400 500 x 3813Hz 6 C 180 37 H2 6 2Fout J S026Hz13 Feu 27057Hz 6 3Fout Revolution around outer race ear of balls or rollers Nonuniform radial tension of bearing Cavities spalling on rolling elements Misalignment of outer race Defects on several bearing surfaces wear of outer race Slip of race Cavities on outer race 135 5241 Defects Wear of inner race Matidentified changes in vibration Cavities on inner race Display diagnosis by the envelope spectrum EI The menu of the Details window contains the following com mands Displays diagnosis by the envelope spectrum This command equals to the Envelope button in the speed bar 4 28 Envelope History Direct Direct History Close Operator s Guide DREAM Displays diagnosis by the envelope spectrum history This com mand equals to the Env History button in the speed bar It will be disabled if you measured only one spectrum for this measurement point or checked off the History check box in the Diagnose New Spectra dialog box The command allows you to display diagnoses for the previous spectra compare two spectra and see how the defect has developed do it by clicking the Envelope and Env History buttons in turn Displays diagnosis by the autospectrum This command equals to the Direct button in the speed bar This command is disabled for the measurement points tha
13. ELEMENT BEARING AND SHAFT LINE Configure this measurement point type the same way as the rolling element bearing Choose only the Rolling element bearing and Shaft Line on the first stage of configuration Fig 3 4 There are differences in the defect list on the last stage of configuration in regard to the shaft coupling This measurement point type is required not only the envelope spectra as for the rolling element bearing but autospectra as well 3 1 4 CONFIGURATION OF THE FLUID FILM BEARING Configuration of the fluid film bearing is done the same way as for the rolling element bearing excluding the bearing selection which is absent The list of the defects that can be indicated differs certainly So refer to Configuration of the Rolling Element Bearing section For configuration of the fluid film bearing the following windows are used the bearing type selection window Fig 3 4 the frequency parameters window Fig 3 9 the defect levels window Fig 3 10 3 1 5 CONFIGURATION OF THE FLUID FILM BEARING AND GEARBOX In addition to the Fluid Film configuration you must specify the gearbox To configure a point of this type 1 Select the Fluid Film and Gearbox in the first section of the configuration dialog Fig 3 4 2 Select orspecify the gearbox type as well as frequency parameters Fig 3 13 3 14 3 Set up or confirm defect levels Fig 3 10 DREAM Chapter 3 Operating the DREAM Program 3 13
14. OF PROGRAM OPERATION Here we will discuss an optimum way of DREAM operation once you have configured you database and how use the system as a condition monitoring and predictive maintenance tool First of all when you come to your office you can issue the Points To Be Measured report for the whole equipment for today or for any later time e g by the next Monday if you are not going to work on weekend You can analyze the amount of work to be done during this period Next you set up the corresponding route in the Sentinel software load itinto the 2526 data collector make measurements and unload them into Sentinel Then exit Sentinel and start DREAM In DREAM select one by one all the units from which the measurement points were measured Once you selected a unit click the right mouse button to display the floating menu and select the Diagnose command from it Fig 3 44 The floating DREAM for Sentinel menu is the most DataBase Measurement Point Spectra Heports Help convenient way to work with the plant Colibratior tree It is simply accessed by the right Bl Demo Plant mouse button Balancing vite de Montr al Filtration amp twater g Deshumidificateurs g Poste de chlare g Compresseurs Diagnose 3 36 Operator s Guide DREAM Inthe DREAM main window you can get an additional menu which contains the main commands To do it select any element of the plant tree and click right mouse button
15. Refine the defect type it means that a defect is found but the type of it can not be determined actually it may be not a defect of a bearing for example but an interference from other units Check the lubrication quality defect of lubrication was detected that usually results in the increase of high frequency vibration level Replace the bearing dangerous combination of defects occurs This recommendation is given when the system considers that in the next 1 of MTBF 10 of the bearings in such a condition may fail Correct misalignment it means that a mounting defect of the bearing was found a misalignment of inner and outer races This is not a very dangerous defect that leads to immediate failure of the bearing but it significantly decreases the service life of the bearing Correct nonuniform radial tension it means that a mounting defect of the bearing was found a nonuniform clearances This is not a very dangerous defect that normally does not lead to immediate failure of the bearing but it may significantly decrease the service life of the bearing Note sure to scroll the lists of defects and recommendations to view all the defects and recommendations issued by the program Click this button to close the window DREAM 4 3 5 ANALYSIS Fig 4 14 The main window of PLOT program that is used for analysis and diagnostics of spectra within DREAM soft ware 1 Chapter 4 Menu Description 4
16. The Diagnose New Spectra dialog box will be displayed Check on the New Only check box select one by one all machines and measurement points from the lists and diagnose all the new spectra In case of doubts in diagnostics you can use the Details and Expertise modes to confirm the diagnosis After you finished with one unit select another one in the plant tree and process all spectra When you have processed all new spectra it is worth creating new reports Conditionsto print the updated report on condition of your equipment with the dates ofthe next measurements it can help you to optimize orders for the spare parts so that you minimize the stock and have enough time to order only the needed ones in advance and Recommendationsto plan the maintenance works You can print separate reports for Bearings To Be Replaced by including only this recommendation in the list Bearings To Check the Lubrica tion or Bearings With Mounting Defects by including in the list only some of recommendations This can be rather helpful when different persons are responsible for certain corrective actions sometimes it may be worth printing the Bearing History reports to make a decision whether to replace a bearing or not Usually DREAM recommends to make only 5 7 measurements during the bearing service life and you can see how the defects change and develop within a bearing Typical situation is when first a small wear of say the outer race develops th
17. defect zone and by the quick development of the defect level The defect can appear in any stage of bearing operation and significantly decreases its service life Wear of balls rollers or cage This bearing defect appears during machine operation resulting in pitting of a part of one or a group of rolling elements It is characterized by a periodic increase in the friction coefficient during cage rotation reaching maximum when the maximum load is applied to the defective element Appendixes Glossary 5 5 Cavities spallings on balls and rollers This bearing defect is the result of wear or shock impacts on rolling elements There is a possibility of the appearance of this defect as a result of rolling elements production facing It is characterized by the appearance of rolling elements impacts on races The defect leads to rapid wear of rolling element surfaces and the cage which results in a significant decrease of service life Complex defect on two or more roll surfaces This bearing defect consists of two or more defects of different roll surfaces t appears in the final development stage of the single surface defects and represents a danger for future opera tion because of the possible appearance of dynamic loads applied to the cage This can lead to cage break Slip of race This bearing defect is the result of slackening one of the race fit in the mounting seat The defect can appear in any stage of machine mounting
18. of outer race 80 x 802 Cavities on outer race 12 150 Wear of inner race Cavities on inner race Wear of balls or rollers Cavities spalling on rolling elements 14 70 Defects on several bearing surfaces Slip of race Defects of lubrication Motidentified changes in vibration 80 03 Mext Heasurement 10 05 56 Recommendations Refine the defect type Replace bearing The severity of the defects is represented by a color green incipient yellow medium red severe Besides for each defect found the program presents its severity in modulation index and probability for a defect to be of this particular type in the parentheses Please refer to the 4th part of this manual for the table of probabilities A defect may be not seen Use the scroll bar to view the whole list of defects Each defect or recommendation of the list has a check box If you check a box near a recommendation the program will check the boxes near the defects that were the reasons for this very recommen dation Detailed Diagnostics Revolution around outer Monuniform radial tension of bearing Misalignment of outer race x Wear of outer 80 802 Cavities on outer race 12 50x Wear of inner race Cavities on inner race Wear of balls or rollers x Cavities spalling on rolling elements 14 70 Defects on several bearing
19. ofthe bearing itself but in many mechanisms the forces increase in the bearing which decrease its service life Such a situation is abnormal and it should be identified during diagnos tics The revolution can be a result of rotor imbalance misalign ment of half coupling connecting the rotors of different ma chines self excited rotor oscillations and so on Nonuniform radial tension of bearing Nonuniform radial tension is the bearing s state when the radial load on the friction surface is significantly dependent on the angle ofthe inner rotating race position It is the bearing unit s defect which influences its service life It can for example lead to seizure of the bearing slip ofthe races in the housing and even the cage or race breaks Usually such a state is caused by the defects in a bearing s housing production or high axial loads and is detected during quality control after housing production maintenance of the machine or in the beginning of machine operation Misalignment of the outer race The misalignment of the outer race is the bearing s state when the maximum load applied to the races is concentrated in two Operator s Guide DREAM opposite points of the outer race It is a result of a maintenance defect of the bearing unit and can lead to rapid wear of races in the points ofthe maximum load The situation is detected during quality control of the bearing unit the replacement of the bearing or in the beginni
20. to existing Sentinel directory is displayed select Browse button and find it manually 2 4 Operator s Guide DREAM Fig 2 6 MERCIE The Backup Replaced Files dialog backup Replaced Files This installation program can create backup copies of all files replaced during the installation Do you want to create backups of the replaced files ves C Cancel Selecting the backup option Yes enables you to revert your system to the pre installation state in the case of uninstallation Although it may be useful only if no other programs will be installed in period between the installation and uninstallation Fig 2 DREAM for Sentinel 2 1 Installation The Select Program Manager Group Select ProgMan Group dialog Enter name of the Program Manager group to add DREAM for Sentinel 2 1 icons to DREAM for Sentinel Accessones Adobe Adobe Acrobat 4 0 Adobe GAP SDKs Antiviral Toolkit Pro Borland Delphi 3 DREAM for Windows Editors FineReader 3 0 Games Grate NetProducts Using this dialog you may change the name of the icon group for the software or confirm the name displayed DREAM Chapter 2 Starting Up 2 5 Fig 2 8 MERCIET ee meee ere The Ready to Install dialog Ready to install now ready to install DREAM for Sentinel 2 1 Press the button to begin the installation or the Back button to reenter the installation information Cancel The last
21. to the Harmonics command from the View menu To display hide the Harmonic Row The button correspond to the Harmonic Row command from the View menu 4 14 The File menu Fig 4 15 The File menu Exit Operator s Guide DREAM Buttons are used to move the standard cursor t can be moved by the arrow keys too Buttons are used to change the cursor width Buttons are used to move the Harmonic cursor It can be moved also by the Ctrl gt arrow keys buttons are used to move the Harmonic Row cursor It can be moved also by the lt Ctrl gt lt Alt gt arrow keys Click this button to copy the active window contents and put it on the clipboard This button correspond with the Copy command from the Graphs menu Click this button to copy the active window contents into file This button correspond with the Copy 10 command from the Graphs menu Click this button to print the active window This button corre spond with the Print command from the Graphs menu Click this button to view the page layout for printing This button correspond with the Print Preview command from the Graphs menu The window menu bar lists five menu names File View Graphs Window and Help This menu contains the single command Exit spectra Display Measurement Point Be Analysis View Graphs Options Window Help Ser Exit qu ST ee program Closes the Spectra Display window DREAM Chapte
22. when you will close and open database next time DREAM Chapter 3 Operating the DREAM Program 3 9 3 1 2 CONFIGURATION OF THE ROLLING ELEMENT BEARING AND GEARBOX If you have to configure a rolling element bearing of gearbox choose this option in the Measurement Point Configuration dialog box and confirm it by the Next button Fig 3 12 The starting window of the Con figuration dialog for choosing the Mea surement Point Type Measurement Point Configuration Measurement Point Type Induction motor Induction motor Sunchronaus machine Pump impeller Fan turbine wheel Rolling bearing and shaft line Rolling element bearing Rolling bearing and gearbox Fluid film bearing i After clicking the Selectbutton at the intermediate window which is appeared and choosing a bearing designation at the Bearing Selection window more detailed description of these operations you can get in previous section 3 1 1 Configuration of Rolling Element Bearing which one you confirm by clicking the OK button the intermediate window appears again with inputted parameters of the chosen bearing Click the Next button and the gearbox configuration window should be present Fig 3 13 The Mea surement Point Con figuration dialog box Measurement Point Configuration i in which there is the drop down list box of gearbox types yet configured gm arm Ix es E Ig r3 c Termo el d
23. 3 1 6 CONFIGURATION OF AN ELECTRIC MACHINE INDUCTION MOTOR SYNCHRONOUS MACHINE At the Configuration dialog box Fig 3 4 choose the Measure ment Point Type Induction Motor or Synchronous Machine and click the Next button At the Frequency parameters window Fig 3 9 putin the Rotation Speed Variation and Max Variation and click the Next button The Electric Machine Setup section appears Fig 3 16 The Electric Measurement Point Configuration Machine section of configuration Main supply frequency Hz Co o Humber of slots in the rotor Point for tangential measurements Put in Mains Power Supply in Hz and Number of slots Number of slots in the rotor for induction motor number of bars rods for the squirrel cage type rotors or the number of slots for the phase type rotors Number of slots in the stator for synchronous machine Note f you do not know the actual number of slots in the majority cases you can define this number by the analysis of autospectrum of electric machine body vibration To do this look for the slot passing frequency and divide it by the rotation speed Point for Tangential Measurements Choose a measurement point in which you will store the tangential measurements results In this case the current machine should contain addi tional point not configured in DREAM Choose a point for tangential measurements from the list box If there are no additional points configured in DREAM fo
24. 6 CONFIGURATION OF AN ELECTRIC MACHINE INDUCTION MOTOR SYNCHRONOUS MACHINE 3 12 3 1 7 CONFIGURATION OF A BLADED MACHINE PUMP TURBINE 3 13 3 2 SETTING UP MEASUREMENTS ee eene 3 15 3 3 GETTING ROUTE MAPS 3 19 3 4 COLLECTING AND PROCESSING 3 20 3 5 DETAILED DIAGNOSTICS 3 21 SION DIET 3 23 3 5 2 EXPERTISE lt trek edt enr uia Te revue 3 26 AM rn 3 27 3 7 REPORTING ccccseccccsescccseccccececesesencseceesseceveversueneneusessensencsessnsasens 3 31 3 8 RECOMMENDED MODE OF PROGRAM OPERATION 3 35 DREAM Chapter 1 Specification A MENU DESCRIPTION Ta qus M utet eres ntn eS dE 4 1 4 2 THE DATABASE MENU epa EUIS e mud 4 1 4 3 THE MEASUREMENT POINT MENU sese 4 2 CONFIGURATION iati ia RUE Ob A a EEUU 4 2 2o V TU t 4 8 Zo V MAIBNIENANUE 4 9 A 3 4 LAST BESULEI Sa ipium eene Ri eire dedu 4 11 A 9 9 ANALYSIS amete diti tu IUE Menit tUe Maid 4 13 Tuis MENG cetus tocum I s One 4 14 THE MEW MENU titu b Debet d eben Dada ra fied 4 15 THE GRAPHS MENU eu Che teo TD 4 17 THE OP THONSIMENY 55d satis ceut atu TE osse SERE uM 4 20 TH
25. Diagnostic Rolling Element Analysis Module DREAM Version 4 x for the Bruel amp Kjaer Type 7107 M Sentinel software and Type 2526 data collector USER S MANUAL OPERATOR S MANUAL Copyright 2003 05 VibroTek Inc Copyright 1996 97 VAST All rights reserved DREAM ABSTRACT Chapter 1 Specification 1 3 DREAM is the Diagnostic Rotating Element Analysis Module It is a software that runs on the IBM PC AT compatible personal computer and when coupled to an FFT analyzer or data collector fited with an envelope detector forms a complete monitoring system for rolling element bearings The software is designed to be used either by nonspecialized maintenance team mechanics not trained in diagnostics or expert alike high level engineer According to the diagnostic unit specified the program recom mends a measurement setup of the data collector After the measurements are done the data are downloaded to the computer and the DREAM makes analysis of the unit current condition DREAM identifies up to 14 possible machine units defects in three levels of danger According to its condition DREAM determines when the next measurement should be made or recommends what maintenance should be made or recommends to replace the unit Since everything can be made in an automatic mode the program works extremely efficient An operator can process up to a 100 spectra an hour and working in one shift a team of two mechanics can m
26. E WINDOW ater peau drea o Peu ex Eres RU Pans 4 21 TRES EER MENU poenitet ope eub dra aua so 4 22 qo DELETE DADA Miti Miti isa s 4 23 42 THE Or EC MIEN nan nU 4 23 2 5 FHE REPORTS MENU a us 4 29 4 5 1 THE STATISTICS 4 30 4 0 2 POINTS CONFIGURA FION uen uite Rn nk ES 4 33 4 5 3 MEASUREMENT SETUPS iiit ia ad dea Don RH EEPRI TOU EN 4 33 4 54 POINTS IOXBE MEASURED assistit utate dista Uri ttai 4 35 CONDINON S iR Sue C Poeti texas Eas erts 4 36 4 5 5 HECOMMENDATIONS 535 5 0 adistete en quai cia 4 37 qo bo b unte a bwennb 4 39 Z5 THE HEEP MEIN tutte dne Deva v datus 4 40 A ls FLOATING MENU EI 4 41 APPENDIX 1 THE FILES OF THE DREAM FOR SENTINEL SOFTWARE 5 1 GLOSSARY eisena Teen N E E a a Quse 5 2 1 5 1 6 1 SPECIFICATION Operator s Guide DREAM Detects and identifies the unit s defects after mounting and during operation Diagnoses the unit s condition by one vibration measurement Makes a long term prediction of the unit s condition by one vibration measurement 1 1 WHAT THE DREAM PROGRAM DOES a a a a 1 2 DREAM FEATURES Collects and saves the data about the units condition during their operation Automatic processing of the envelope spectrum and mean high frequency bearing housing vibration detecting the diagnostic parameters and di
27. Fig 3 3 The Mea surement Point Con figuration dialog box Is used to set up a point in the DREAM database To configure a measurement point select it in the plant tree and use Configuration command from the Measurement Point menu DREAM for Sentinel DataBase opectra Reports Help Configuration Copy Configuration Ctrl C Delete Data Ctrl Del Setup Maintenance Last Results Analysis This command displays the Measurement Point Configuration dialog box Measurement Point Configuration Measurement Point Type 15 not chosen nat comesponded to hardware key hi asimum Control Period days This dialog box contains several pages that can be switched by Next andPrev buttons Here you have to choose the Measurement Point from the corresponding drop down list box and set the Maximal Control Period in days This parameter is used to plan the measurement schedule If there was no defect found in this measurement point the program would suggest to measure it next time in this very number of days if some defects will be found this period will be decreased depending on the types and severities of the existing defects For rolling element bearings it is recommended to state this period equal to 20 of MTBF for this very type of DREAM Chapter 3 Operating the DREAM Program 3 3 bearing under these very operation conditions on this very ma chine Fig 3 4 The drop do
28. Only those side bands are displayed that fit in the closest half of the interval between nearby harmonics others are hidden the distance between sidebands in the Harmonics cursor You can enter it or select one of the most typical frequencies from the list box Click the OK button to apply changes and close this dialog or Cancel button to disable changes DREAM The Window menu Fig 4 25 The Window menu Cascade Fig 4 26 The windows ar ranged in cascade Tile Chapter 4 Menu Description 4 21 The Window menu includes the commands for windows manage ment spectra Display Measurement Point Be Analysis File View Graphs Options um Arrange Icons 1 Date 3 0 Plot 3 Section 4 Analysis Cascade windows The first part of this menu contains three commands This command arranges open windows so that they overlap each other with the title bar of each window remaining visible Spectra Display Measurement Point B File View Graphs Options Window Help MEEA Section 3 D Plot Date Analysis This command arranges open windows so that no windows overlap and all windows are visible 4 22 Fig 4 27 The windows ar ranged in tile Arrange Icons The Help menu Fig 4 28 The Help menu About Fig 4 29 The About information box Operator s Guide DREAM spectra Display Measurement Point Be File View Graphs Options Window Help
29. a 1 3 octave band but the choice of the actual band should be done after the analysis of the autospectrum in this point The detailed description of how to choose that frequency band for the envelope analysis can be found in the third part of this manual but the basic rule says look at the shape of the autospectrum in the region of the recommended bandpass filter If there are some DREAM 3 3 GETTING ROUTE MAPS Fig 3 24 The Points To Be Measured report Chapter 3 Operating the DREAM Program 3 19 resonances or strong harmonic components it is recommended to set the bandpass filter to the nearest flat region of the autospectrum This way you have to configure all points for DREAM in the sentinel database Once measurement points are configured DREAM can form a list of bearings to be measured To do it select a node on the plant tree in DREAM and choose the Points To Be Measured command from the Reports menu PrePrint meas qrp Points to be measured by 30 Oct 1887 10097 3 14 13 PLI 3 Hazel FEH 14 Domen O oren exse 969 wm 9 eee 29 a e ae EM E pa fe a Ub bm d d 2 9 When DREAM will diagnose some spectra it will give either a recommendation on some corrective action
30. al tension it means that the mounting defect of the bearing was found the nonuniform clearances This is not a very dangerous defect that normally does not lead to immediate failure of the bearing but it may significantly decrease the service life of the bearing The recommendations are included in the report in the form of numbers Their meaning is described at the bottom of the report If there are no recommendations then a message appears Error STOP Report is empty DREAM Chapter 4 Menu Description 4 39 4 5 7 HISTORY This command displays the History report This report contains information about all measurements and the results of diagnostics that were made for this measurement point Fig 4 49 The History report Page Zoom Lr pde MAHAR e ed S PrePrint hist qrp 10220297 1 08 17 PM TEC Turbiniy ceh Fitatelnie 8 1v Recommendations measurement 08 Feb 1997 Defect levels probabilities i Date Tire 2011 07 4 52 26 Jos arm 45030 P B Defect levels Incipient 1 Unbalanced rotor Db 0 Shaft feouplirig wobbling Defects of support structure Dk Selfsustained shaft vibration 95 Misalignment of the bearing The defect severity is presented in the percentage of modulation figures and three degrees of severity severe medium incipient letters and marked by differe
31. an see in this dialog box the list of the bearings gearboxes configured in the database and how many times they are used in measurement points configuration It can be useful for example if you want to know whether you need the bearing of this type Or if you configured an improper bearing and that caused wrong diagnostics you need to know in which points it is used delete the data and re configure these points Only then you can delete the improper bearing When to find points with the improper configured bearing you use the Measurement Configuration report select the highest level Only then you find all the similar points In another way you can get program message The report is empty To issue a statistics report 1 Select a component type bearing or gearbox 2 Select from the list a bearing gearbox the type you are interested in 4 32 Fig 4 40 The List of Bearings report Operator s Guide DREAM 3 Select a type of the statistic report Confirm your choice by the OK button or escape this dialog by the Cancel button The report will be issued on the selected bearing designation or gearbox type The form of the statistic reports Measurement Points Conditions Recommendations is the same as the non statistics ones that are described below The List of Bearings you can get only by the Statistics command It is independent report its contents are not depend on your selections It tells about all the
32. and operation The bearing s operation with such a defect is undesirable Such a bearing must be replaced as soon as possible Defects of the lubrication This bearing defect is characterized by an increase in the friction forces with the absence of any other types of developed defects The defect can be a result of the lack or excess of lubrication in the bearing destruction of lubrication structure or impurities in lubrication The defect can appear in any stage of a bearing s operation and significantly decreases its service life The defect must be corrected as soon as possible Designation A name under which the bearings are listed in the manufacturer s specification documents where all the technical data of the bearings are given The program has only one file with such data and takes all its specification data from this file You do not need to put in these data every time you describe the bearing the program will take these data by itself from the database There is a designation library in the program that contains almost all the Soviet made bearings and the designa tions of the bearings of the most common western manufactur ers Din The diameter of the bearing s inner race or inner raceway In the latter case Dout must be the diameter of the outer raceway 5 6 Operator s Guide DREAM dNrol The acceptable variations in the number of rolling elements set by the operator During the analysis ofthe envelope spectrum the pro
33. and specifications of the bearings included in the bearing database These are the bearings that you have on your plant at any measurement point This report is issued for all the equipment ts contents are not depending on the node or bearing designation you have selected This report is created with the command Statistics For each node ofthe plant tree there can be generated the following reports Contains information on the type of measurement points config ured inthe DREAM database the designation ofthe installed units the rotation speed Contains information on the type and setups of measurements required by DREAM for diagnostics of all measurement points These setups depend on the type of the unit to be diagnosed the parameters of the unit and the rotation speed Very important report that is used to plan measurements configured in DREAM measurement points that have not been measured or condition of which should be refined by a certain date are included in the list together with the measurement setup for each point This report presents the information about the condition of your equipment The report contains information when were done the measurements last time for each measurement point when should be measured it next time on the maximum defect level found in the equipment and lists the recommendations for corrective actions to be done This report is a subset of the previous report in which there are includ
34. cs Results dialog box Detects Te evel 1 Revolution aroundouterace 0 S LJ 2 Nonuniformn radial tension of bearing 3 Misalignment of outer race 4 Wear of outer race 5 Cavities on outer race BiWearofinerrace 1802 Severe 80 7 Cavities on inner race 8 Wear of balls or rollers NENNEN DENEN 4 Cavities spalling on rolling elements 133 Severe 0X l Defectsonseverlbeaingsufaces Defects of lubrication Next measurement 10 May 1996 Recommendations Replace bearing 1 Here all the defects their severities and probabilities are listed together with the recommendations on maintenance and date of the next measurements The following fields are displayed in this dialog box This table contains all the defects that can be found by the DREAM software for this type of measurement point The defects that have been found have the severity and probability on to be the defect of this very type The condition prediction or the non failure operation time for this measurement point If this date have passed it is painted with the eae MEE CC red color It means that the system is unsure about the current condition of the unit and you should check its condition by new measurements and diagnostics Recommendations Recommendations for corrective actions to be made for this measurement point Possible recommendations are
35. cts on several bearing surfaces Slip of race Defects of lubrication Notidentified changes in vibration 80 x 0 Next Measurement 10705796 Recommendations Refine the defect type Replace bearing The dialog box contains three fields a list of defects date of the next measurement prediction of the non failure operation period and a list of recommendations The severity of the defects is represented by a color green incipient yellow medium red severe Besides for each defect found the program presents its severity in modulation index and probability for a defect to be of this particular type in the parentheses Each defect or recommendation of the list has a check box If you check a box corresponding to a recommendation the program will check the boxes near the defects that were the reasons for this very recommendation The following buttons are used in this dialog box saves the results of diagnostics in the database and closes Detailed Diagnostics dialog box Displays the spectrum with all lines and the defects found In this mode DREAM can display you the diagnostic symptoms for each defect or recommendation eis E CC Displays the expertise of the spectrum including all recommenda tions with reasons for them all the defects with their reasons all warnings or comments in the text form Fig 4 34 The Exper Expertise tise information box RECOMMENDATIONS Refine the defec
36. dialog box you can setup your printer set the print range the number of copies etc The Exit button is used to close this window issue a report choose a node in the plant tree and use the corresponding command from the Reports menu DREAM for Sentinel DataBase Measurement Point Spectra 9 005 Statistics g Flant configuration B Balancing Measurement Setups Points to be measured Conditions Recommendations History vite de Montr al Filtration amp twater Jl D shumiciticateurs Jl DREAM Chapter 4 Menu Description 4 31 4 5 1 THE STATISTICS COMMAND Fig 4 39 The dialog to choose a bearing designation or gear box type for reporting Note Besides the reports on the selected node you can get the statistics reports on the selected bearing designation or gearbox type They are List of Types Measurement Points Conditions Recommen dations To issue a Statistic report select the Statistics command from the Report menu It calls the Statistic Report Settings dialog box statistic Report Settings Designation Used f DESSERT TN RR suivel30 0 1502314 1 1502317 su2322 a3 sua m Rmo f 1 Configuration arid 1 Condition EL EN 1 Recommendations eS By this dialog box you can choose the component type bearing or gearbox on which you want to issue a report and type of report as well You c
37. dialog where you may yet change the information being entered Click the Back button to do it or the Next to start copying process In order to work with databases the program need the Borland Database Engine to be installed It is the shared component which may be used by many programs The following dialog will be displayed to select a directory for the BDE installation Fig 2 9 Borland Database Engine Location x Selecting a directory for Borland Database The Borland Database Engine is shared software Engine component that provides common database layer for applications Please edit the field below to install the Borland Database Engine to a different directory Press the button to continue Press Cancel to abort the installation 2 6 Operator s Guide DREAM After the copying process illustrated with the process bar is completed the message on it will be displayed Fig 2 10 DERTTE Message on installa tion completion Installation Completed The installation of DREAM for Sentinel 2 1 has been completed Press the Finish button to exit this installation Cancel After the installation of DREAM for Sentinel insert disk labeled Security into your floppy drive From the Program Manager go to the File menu and select the Run Type or select by the Browse file DDINSTAL At the dialog box appeared press the Express button Gol Device Driver Installer for Yin 3 1x and Vin 95
38. e Select the desired node with the left mouse button and press the right mouse button anywhere on the desk top DREAM Appendixes Glossary 5 APPENDIX 1 THE FILES OF THE DREAM FOR SENTINEL SOFTWARE The following files are located on the Sentinel directory dream fs exe The main executable of DREAM for Sentinel preprint exe Report Preview main executable Additional modules required by DREAM for Sentinel com 16 dll bc453rtl dll bids47 dll plot exe edd dll plotlib dll oriondb dll 0 1253 4 rdm330 dll dream hlp detaildl dll Files located in the DLL subdirectory omdlirdm dll library required by DREAM for Sentinel Database of DREAM for Sentinel is located in the DREAMDB subdirectory and consists of the following files bearns db mpoints db rtyp_10 val bearns px mpoints mb rtyp_10 x02 bearns val mpoints px rtyp_10 y02 bearns x02 mpoints val rtyp_4 db bearns y02 mpoints x03 rtyp_4 px defects db mpoints x04 rtyp_4 val defects px mpoints y03 rtyp_4 x02 defects val mpoints y04 rtyp_4 y02 defects x05 mptypes db rtyp_6 db defects y05 mptypes mb rtyp_6 px dirparam db mptypes px rtyp_6 val dirparam px mptypes val rtyp_6 x02 dirparam val mptypes x06 rtyp_6 x03 elmach db mptypes xg rtyp 6 y02 elmach px mptypes y06 rtyp 6 y03 elmach val mptypes yg spectra db elmach x02 otree db spectra mb elmach y02 spectra px envparam db results db spectra val envparam px results mb strings db envparam val results px string
39. e Envelope button from the speed bar Displays diagnosis by the envelope spectrum history This com mand equals to theEnv Historybutton from the speed bar It would be disabled if you measured only one spectrum for this measure ment point or checked off the History check box in the Diagnose New Spectra dialog box The command allows you to display a diagnosis forthe previous spectra compare two spectra and see how the defect has developed do it by clicking the Envelope and Env History buttons in turn Displays diagnosis by the autospectrum This command equals to the Direct button in the speed bar This command is disabled for the measurement points that do not require autospectra for diagnostics e g for rolling element bearings Displays diagnosis by the autospectra history This command equals to the Dir History button in the speed bar This command is disabled forthe measurement points that do not require autospec tra for diagnostics e g for the rolling element bearings Closes this window Diagnosis Envelope elope Env Histery Direct Aleta Direct Close Alt FA 7 80 0 100 200 300 400 500 600 700 800 900 1000 15 25 14 19827Hz 13 4 48973Hz 7X 299 55 Hz 21 Frat 599 05 11 4 oF rot H3541Hs 124 12Frat 93 67 Hz 14380Hz 6 3Frot C Unbalanced rator Shaft coupling wobbling Defects of support structure Selfsustai
40. e button The spectrum will be processed auto matically and the results of diagnostics displayed in the Detailed Diagnostics dialog box see the next section Detailed Diagnostic Use scroll bar to check all the defects in the list Click Done button and the diagnostic results will be saved in the DREAM database for future reporting This way you can process all new spectra from the Sentinel database This mode is an optional utility that displays you the diagnostic process and explains why the DREAM says that this type of defect is found in the measurement point and why this or that recommen dation is given In other words it provides an operator with all available data to make a correct decision about the condition of the unit The starting point for this mode is the Detailed Diagnostics dialog box that appears on the screen as the result of diagnostics for any spectrum see Fig 3 25 The dialog box contains three fields a list of defects date ofthe next measurement prediction of the non failure operation period and a list of recommendations 3 22 Fig 3 27 The De tailed Diagnostic dialog box with the list of defects and recommendations Warning Fig 3 28 Check a check box of the recommendation to see the reason for this very recommen dation Operator s Guide DREAM Detailed Diagnostics Revolution around outer race Nonuniform radial tension of bearing Misalignment of outer race Wear
41. e that is used to work with databases Security software to install driver for the hardware protection key to work with Windows You should use the SETUP program to install DREAM software onto your computer system This will insure that all the files that form the DREAM software would be transferred to the right place SETUP will automatically create the directories and copy files from the distribution disks to your hard disk To install DREAM for Sentinel follow the instructions below To start installation 1 Launch Microsoft Windows 2 Insert disk DREAM for Sentinel Setup 1 into your floppy drive 3 From the Program Manager go to the File menu and select Run command Under Windows 9x select Run from the Start button menu Another way is to select Start gt Settings gt Control Panel and on the Control Panel displayed Add Remove Programs 2 2 Fig 2 1 Use command Run from the File menu of Program Manager to start the installation process Fig 2 2 Enter the setup exe file name and click the OK button Note Fig 2 3 Starting installation window Operator s Guide DREAM Program Manager jw File New BEI Accessories Open Move Copy F Delete Properties Alt Enter Hun ia Terminal Notepad Cardtile Calculator Clock 4 Type a setup in the Run dialog box and press OK button or use the Browse button to select the setup exe file Command Li
42. e type and setups of measurements required by DREAM for the diagnostics of all measurement points These setups depend on the type of the unit to be diagnosed the parameters of the unit and the rotation speed Here are Measurement Point contains the name of the measurement point Measurement Type may be either Envelope or Auto spectrum F span is the Frequency Span to be set in the Sentinel mea surement setup It is the span of the analysis F low is the Lower Frequency to be set in the Sentinel mea surement setup for the envelope spectra F high is the Upper Frequency to be set in the Sentinel mea surement setup for the envelope spectra F centr is the Center Frequency to be set in the Sentinel measurement setup for the zoomed autospectra F low and F high form the bandpass filter for envelope detector The report is used to look at the measurement parameters required for DREAM diagnostics you need to set up in the Sentinel DREAM Chapter 4 Menu Description 4 35 4 5 4 POINTS TO BE MEASURED Fig 4 43 Select Measurement Date dialog box b Cancel Fig 4 44 The Points To Be Measured report By this command DREAM will automatically check the diagnosed conditions of your equipment and include in the list only the measurement points for which the condition prediction is expired by the stated day This command displays the Select Measurement Date dialog box Set Maintenance Date aa October
43. earing library To make a choice select the desired bearing and click the OK button This dialog box has the following controls A text box that is used to find the desired designation When you enter the first symbols of the designation the list advances to the corresponding names Click this button to accept choice and add the selected designation to the DREAM database and close the dialog box Click this button to disable your choice and close the dialog box Once you click the Next button at the second section of the Measurement Point Configuration dialog box you advance to the next section Measurement Point Configuration Hotation Speed Variation Max variation X oa 0 The third section has the following controls An input box to enter the rotation speed of the machine in Hz An input box to enter possible variations in rotation frequency from measurement to measurement From the point of the program the variations could be normal set by the operator for example Rotation Speed Variations or Max Variation The more Variations and Max Variations are the less the certainty the probability of the exact type of the defect that is displayed by the program and it takes more time to make the diagnostics Ifthe actual rotation speed is not within Variations but within Max Variations the program identifies the type of the defect but gives DREAM Max Variations lt lt Prey E
44. ed only the measurement points that have some recommen dations When you create this report the program asks you which 3 32 Operator s Guide DREAM of recommendations to include in the list The possible recommen dations are Refine the defect type it means that a defect is found but the type of it can not be determined actually it may be not the defect of a bearing for example but an interference from other units Check the lubrication quality the defect of lubrication was detected that usually results in the increase of the high frequency vibration level Replace the bearing dangerous combination of defects occur This recommendation is given when the system considers that in the next 1 of MTBF 10 ofthe bearings in such a condition may fail Correct misalignment it means that the mounting defect of the bearing was found the misalignment of inner and outer races This is not a very dangerous defect that leads to the immediate failure of the bearing but it significantly decreases the service life of the bearing Correct nonuniform radial tension it means that the mount ing defect of the bearing was found the nonuniform clearances This is not a very dangerous defect that normally does not lead to immediate failure of the bearing but it may significantly decrease the service life of the bearing For each measurement point there can be shown the History Contains information of all measurements and the resul
45. ement bearing This command is used to display the information on the measure ment setup that is required by DREAM to process diagnostics for the particular measurement point By this command the Measure ment Setup information box is displayed Measurement Setups Point 1 Rotation Frequency Hz 50 Status 1000 7080 8910 There may be one of or two sections if necessary for measurements Envelope Spectrum Autospectrum Here DREAM Fig 4 10 The Measurement Setup information box with the Autospec trum section visible Note 4 3 3 MAINTENANCE Chapter 4 Menu Description 4 9 F span is the Frequency Span to be set in the Sentinel mea surement setup F low is the Lower Frequency to be set in the Sentinel mea surement setup F high is the Upper Frequency to be set in the Sentinel mea surement setup The Status column may contain letters L R A that mean L leading spectrum that is presented in reports R required spectrum A additional spectrum Measurement Setups Point w Rotation Frequency Hz 50 Baseband 2000 A Type can be Baseband or Zoom to be set in the Sentinel measurement setup Due to the fact that Type 2526 data collector can measure only 400 lines resolution spectra in some cases DREAM will require to measure two spectra with different settings for diagnostics for example a bearing with a number of balls more than a hu
46. en in half a year it transforms in medium cavities on the same race then in 1 3 months it changes up to severe cavities and medium wear of the same race and some medium defects on another one and in this case you have to be more careful and measure more often As soon as another severe defect develops cavities on the inner race or rolling elements this usually happens after another 2 weeks 2 months DREAM recommends to replace the bearing DREAM Chapter 4 Menu Description 4 1 4 MENU DESCRIPTION This chapter of the manual will describes all the commands and features of the DREAM software 4 2 THE DATABASE MENU This menu is used to work with database Fig 4 1 DREAM for Sentinel Menu Database of Reports Help the DREAM software Plant 4 g Test 1 Machines The following commands are included in the menu Open Opens the database of Sentinel and reads all plants structure and spectra that can be used by DREAM for diagnostics Note start DREAM and open the database of Sentinel you should exit Sentinel Otherwise this command will be disabled When DREAM reads all the spectra it closes the Sentinel database and you can work simultaneously with Sentinel and DREAM View This command can be executed independent on the database of sentinel being opened By this command DREAM 1 Opens its database in the same state as it was closed last time In this case new spectra from the Sentinel database ca
47. eshumidificateurs PROCEDE i The command is used to diagnose spectra and store results of diagnostics in the DREAM database Note the higher level you choose the more measurement points you can diagnose but not higher than the machine group By this command the Diagnose New Spectra dialog box is displayed Diagnose new spectra D shumidificateurs Machines Measurement Points Hew Spectra PROCEDE1 4 16 96 6 43 16 5 9 96 4 57 10 PH X History DREAM 3 5 DETAILED DIAGNOSTICS Chapter 3 Operating the DREAM Program 3 21 If in the plant tree you have chosen a machine group node you can choose a machine from the list of machines for diagnostics If you have chosen a machine or a measurement point you can choose only a measurement point and a spectrum In this dialog box you can choose one by one all the spectra for the points below the selected node and process them in turn Choose Machine if possible Measurement point Spectrum Enter or confirm Rotation Speed Only new spectra from the Sentinel database that have not been processed by DREAM are included in the list of spectra when the New Only box is checked n another way you can process the old spectra To diagnose all previous spectra to see the defect devel opment from measurement to measurement check the History check box In the last case much more time may be needed to process all the spectra Click the Diagnos
48. eu 0 27057Hz 6 3Fout Revolution around outer race wear of balls or rollers Nonuniform radial tension of bearing Cavities spalling on rolling elements Misalignment of outer race Defects on several bearing surfaces wear of outer race Slip of race Cavities on outer race 13x 521 Detects lubrication Wear of inner race Matidentified changes in vibration Cavities on inner race Fig 3 31 To display all the lines symp Diagnosis toms for a certain Envelope Env Grece Di etes defect check on the defect check boxes 0 100 200 300 3813 2 x 18037Hz 6 2Fout x 90 26H213 Fout x 270 57 Hz 6 3Fout Revolution around outer race wear of balls or rollers Nonuniform radial tension of bearing Cavities spalling on rolling elements Misalignment of outer race Defects on several bearing surfaces wear of outer race Slip of race EJ Cavities outer race 12x 752 Wetects wear of inner race Matidentified changes in vibration Cavities on inner race DREAM Envelope Envelope History Direct Direct History Close Fig 3 32 The Diag nosis menu with the pop up line at the bottom of the dialog DOX Chapter 3 Operating the DREAM Program 3 25 The menu ofthe Details window contains the following commands Displays diagnosis by the envelope spectrum This command equals to th
49. f race Cavities on outer race 135 521 Defects Wear of inner race Matidentified changes in vibration Cavities on inner race DREAM Fig 4 36 The Diag nosis menu with the pop up line at the bottom of the dialog DOX Envelope Chapter 4 Menu Description 4 27 The results of diagnostics are presented in this window together with the spectrum frequencies and modulation indexes of lines found in the envelope spectrum and their identification The Diagnosis dialog box contains three fields You can change the size of each window by dragging field separators The first window presented a spectrum In the second window all lines found in the spectrum are presented and classified by their origin For example Frot is the rotation speed and Fin are the ball passing frequencies on outer and inner races etc n the third window you can see all the defects found in the bearing When you check on any check boxes for frequencies in the second field the corresponding lines are marked in the spectrum by red lines If you check on the any check box near the defect you will see reasons of defect diagnosis in the first window you will see the lines by which the defect had been found the lines will be marked by red lines in the second window these lines will been checked on E Diagnosis x Envelope elope EnwHister Direct Dir History Envelope History Include in Report
50. fill in the designation and dimensions of the new bearing Click this button to access the bearing library that is supplied with the DREAM software and contains 4000 5000 bearing designa tions from different manufacturers Click this button to delete a selected bearing from the database Click this button to choose a selected designation for the measure ment point and close this dialog Click this button to disable your selection and close this dialog When you click the Import button the Import a Bearing dialog box will be displayed Import a Bearing Designation Din Dout Drol b sKFl 2X351571 380 00 810 00 90 00 9000 15 skroz 1200 4000 5 00 3200 14 _8 900 2500 450 4500 12 8 200 1000 3000 476 1222 0 SKFI2000 1000 3000 476 1221 8 201 1200 3200 475 1270 10 0 SKFi2 E 1200 3200 5 00 1264 10 0 SKFI202 1500 3500 5 58 1254 10 0 L SKFi202E 1500 3500 5 56 1254 10 0 skFin3 1700 4000 556 1161 12 0 8 203 1200 4000 600 1181 1 0 L SKFi204 2000 4700 6 35 1037 12 0 SKFI20M4E 2000 4700 714 1115 12 0 zm xm Mask su Fig 4 7 The third section of the Measurement Point Configuration dialog box is used to enter the parameters of the rotation speed Rotation Speed Variation Operator s Guide DREAM This dialog box lists bearings designations from the external b
51. g abbreviations are used in the list Din the diameter of the inner race or the inner raceway Dout the diameter of the outer race or the outer raceway if Din was the diameter of the inner raceway Note if you do not know the diameters of races you can enter the cage diameter as a diameter of both inner and outer race The program actually needs only the cage diameter that is calculated as a mean value of inner and outer race diameters Angle the contact angle in degrees between the rolling elements and the race DREAM Delete X 4 6 Import a Bearing dialog box is used to work with the external library of bearings designations Chapter 4 Menu Description 4 5 Drol the diameter of rolling elements Nrol the number of rolling elements in the bearing dNrol the acceptable variations in the number of rolling elements set by the operator When analyzing the envelope spectrum the program will correct the number of rolling elements in the limits Nrol dNrol if there is a mistake in the input data If the variations in the number of rolling elements exceed dNrol the program is not able to identify the type of defect Note Our experience shows that it is rather typical for the bearing manufacturers to vary the cage design and thus the number of rollers in the same type of bearing This dialog box has the following controls Click this button to add a blank line to the list where you can
52. gram will correct the number of rolling elements in the limits dNrol if there is a mistake in the input data If the variations in the number of rolling elements exceed dNrol the program will not be able to identify the type of defect Dout The diameter of the bearing s outer race or outer raceway In the latter case Din must be the diameter of the inner raceway Drol The diameter of the bearing s rolling elements Failure Danger The bearing failure danger indication is generated when a slip of the race in the housing or a severe defect of lubrication a severe wear of balls rollers or cage or two and more severe defects of different roll surfaces appear Fin The ball passing frequency inner race F high The high cut off frequency of the band pass filter of the envelope detector that should be set in the Sentinel software for each measurement according to the recommendations of the DREAM software F low The lower cut off frequency of the band pass filter of the envelope detector that should be set in the Sentinel software for each measurement according to the recommendations of the DREAM software Fr The rotation speed of the bearing the shaft Fout The ball passing frequency outer race Frol The rotation frequency of the rolling elements Frot Hz The rotation speed of the bearing Fs Full Frequency Scale frequency that should be set for each measurement in the Sentinel software according to the recom mendations of the prog
53. h the selected Autospectrum sec tion Fig 3 21 The Mea surement Setup information box with the Autospectrum section visible Note Operator s Guide DREAM In this dialog box there can be one or the two sections for envelope and auto spectrum Click the title of a section to see it Measurement Setups Point v Rotation Frequency Hz 50 Baseband 200 A The Status column may contain the letters L R A L leading spectrum that is presented in reports R required spectrum A additional spectrum Measurement Setups Point 1 Rotation Frequency Hz 50 Baseband 2000 A Type can be Baseband or Zoom to be set in the Sentinel measurement setup Due to the fact that Type 2526 data collector can measure only 400 lines resolution spectra in some cases DREAM will require to measure two spectra with different settings for diagnostics for example a bearing with a number of balls more than a hundred For DREAM these two spectra are both one measurement and it will identify this measurement by a time of the leading spectrum So for diagnostics DREAM needs leading and required spectra to be measured additional spectra may be used to refine some types of defects but not required Leading DREAM Fig 3 22 The Mea surement Setups report Chapter 3 Operating the DREAM Program 3 17 spectra are used to identify the measurement and only t
54. he date of leading spectrum is presented in all reports and lists The button OK lets you come back to the DREAM main window The other parameters contains also in the report We return to the Measurement Setups command from the Reports menu The program automatically issues the list that contains required setup parameters for all measurement points in the chosen machine or unit PrePrint setup qrp Page 2E po 131 25 Dialog uni Measurement setups 1 0 30 87 5 11 04 PM 8 Mosenergo Turhbiniy ceh Masosi Pitatelnie 14 Dues eremum sm me ese emm Oper tes 1000 zoso exis emm LET LLL ana me mw ee ae ee 828 E mem 1 3 The report can be printed or saved by clicking the corresponding buttons Click the Exit button to close the report window Now start Sentinel The task is to change the setup for all measurement points that will be used for diagnostics by DREAM To do it choose machine in the plant tree of Sentinel software and enter the Measurement setup We will discuss indetailes the Envelope Spectrum dialog box for envelope spectrum measurement of the corresponding point The settings for autospectra are similar 3 18 Fig 3 23 Measure ment Setup Envelope opectrum dialog box 15 used to setup envelope spectrum measurement in the Sentine
55. ic Row cursor can contain only harmonics not bands 4 16 Fig 4 17 The Harmonics com mand is marked and the button is pressed and harmonics of the chosen frequency are displayed Fig 4 18 The Harmonics Row Command is marked and the button is pressed Operator s Guide DREAM spectra Display Measurement Point Analysis File View Graphs Options Window Help E th 120 0 Hz en o M 100 The harmonics cursor can be used to find sidebands for certain spectrum components see fig 4 16 spectra Display Measurement Point Analysis File View Graphs Options Window Help feda 2 jb seo ell gt The Harmonic Row cursor can be used to find harmonic rows in the spectrum The harmonics cursors appear at the position ofthe standard cursor and can be moved The Harmonics cursor by the Ctrl arrow keys by buttons in the speed bar The Harmonic Row by the lt Alt gt lt Ctrl gt arrow keys or by Alt gt buttons in the speed bar DREAM The Graphs menu Fig 4 19 The Graphs menu for printing and copying commands Copy Copy to Fig 4 20 The Copy Image to File dialog box Chapter 4 Menu Description 4 17 This menu allow you to copy contents of any window in clipboard to paste in any other application e g text editor or saved as a file in the Windows bit map format or printed This menu a
56. in the input data for Rotation Speed 96 at which the program will still identify the type of the defect but will give a warning signal to the operator If the variations exceed the Max Variations value the program will detect the defect and its depth but will not identify the type ofthe defect In this case the type of the defect will be defined as a Not Identified Defect NID If there is such information itis recommended To check whether the processed spectrum belongs to the chosen measurement point To check the data in the measurement point To check data in the bearing s designation make a new measurement Note it is recommended to put in the Variations of about 2 396 and maximum variations not more than 1096 By the above data the DREAM program automatically calculates the severe defect levels You can view oredit them according to your own experience To do it click the Next button The following dialog box will be displayed Measurement Point Configuration ies atk Ee 1 Rev olution around outer race p Monuniform radial tension of bearing Misalignment of outer race Wear af outer race Cavities on auter race Wear af Inner race Cavities an inner race Revolution around outer race 5a X ona 3 8 Fig 3 11 To read spectra for a newly configured measure ment point DREAM needs to reread Sentinel s database Operato
57. ing elements exceed dNrol the program is not able to identify the type of defect 4 5 2 POINTS CONFIGURATION This command displays the Measurement Points report Fig 4 41 The Mea PrePrint point qrp surement Points report Dialog Measurement Points 10 10 96 12 44 55 Ville de Montr al Filtration Atwater D shurniditicateurs PROC D Name AS Fomt Type Rolling elernent bearing Conbiguration Data Bearing Frotation 29 6H2 Pomt Name Be Pomt Type Rolling elernent bearing Conbiguration Data Bearing SEFE303 Frotation 29 6H2 Pomt Name Type Rolling elernent bearing Conbiguration Data Bearing SEFY AR2031H2T Frotation 33 7 The report contains information on the type of measurement points configured in the DREAM database the designation of the installed bearings the rotation speed EM o EM 4 5 3 MEASUREMENT SETUPS This command displays the Measurement Setups report Fig 4 42 The Mea PrePrint setup qrp surement Setups Zoom report of 1 B po 54 Bo 52 131 E B 25 E X Dialog Measurement Setups 10730797 5 11 04 PM TEc 8 Masenerao Turbiniy ceh Nasosi Pitatelnie 14 oman me 9 eem LL Lees mm ww eem LL LLL Tess eeeeemens um mm ww eem opem LL LLL etal Se 0290888 emm o The report contains information on th
58. isplays the Print Setup dialog box Once you click the Printer Setup command in the Graphs menu the Print Setup dialog box appears currently HP LaserJet 5L PCL on Aanton hp LPT1 Specific Printer ur LaserJet 5L PCL on Xantonkhp LPT1 Size User Defined Size Source Paper Input Bin s Y Portrait Landscape 5 This is a standard dialog box of Windows for setting up default printer Here you can set up your printer paper size etc 4 20 The Options menu Harmonics Fig 4 24 The Harmonics dialog box Main Rows Additional Row Side Bands Modulation Frequency Operator s Guide DREAM This menu contains the Harmonics command only The command allows you to set the number of harmonics in the Harmonics and Harmonic Row cursors and number of side bands and modulation frequency for the Harmonics cursor This command is used to set options for two types of harmonic cursors By this command the Harmonics dialog box is displayed Hain How Additional Row Side Bands Modulation Frequency Hz L The rotating rate of the cage Here is the number of harmonics in the main Harmonics cursor is the number of harmonics in the Harmonic Row cursor is the number of the sidebands for each of harmonics in the Harmonics cursor Note that if you have more than one harmonic in this type of cursor not all the side bands may be displayed
59. l database Operator s Guide DREAM Measurement Setup Envelope Spectrum Mame 1 es IX Fnable Make Reference Detector RMS Gain Auto Integrations None Highpass 1Hz Frequency Mode Absolute s AC Gain 40 dB Frequency Span 2K Hz s SURE fo Lower Frequency 0 91 k Hz s Upper Frequency 1 2k Hz Averaging Weighting Mode Trigger Level Here set for each measurement point Averages Number of averages should be in the range 16 30 The more averages you select the more reliable results in diagnostics you receive but the measurements will take more time Averaging Mode Set to Spectrum Weighting Mode Set to Hanging Trigger Set to Free Run Detector Set to RMS Integrations Set to None Frequency Mode Set to Absolute Frequency Span Set as required by DREAM in the Fs column in the Measurement Setup list for this measurement point Lower Frequency Set as recommended by DREAM in the Flow column in the Measurement Setup list for this measurement point Upper Frequency Set as recommended by DREAM inthe high column in the Measurement Setup list for this measurement point All other parameters are not essential for DREAM but of course you should set a proper gain factor The choice of Lower and Upper frequency thus the bandpass filter for envelope detector is a very important factor The DREAM only recommends
60. lanced rotor Dh Shaft icouplina wobbling Defects of support structure Dh Selfsustained shaft vibration 95 Misalignment of the bearing 95 The following controls are used in this window The Page input box to set the page number for display You can use arrows to scroll through a report The Zoom input box is used to setup displaying You can use the arrows advance this control By the arrows you can change zooming in 1096 intervals Click this button to set zoom to 100 Click this button to fit the whole page in the window Scales the editing view to see the width of the page The Load button is used to open your previously saved report to view or print it The standard extension for the report files is QRP The program normally saves only one last report of each kind on disk DREAM Chapter 3 Operating the DREAM Program 3 35 The Save button is used to save a report on disk The standard extension for the report files is QRP The program normally saves only one last report of each kind on disk so to be able to open and print reports later you have to save them manually Click this button to print a report on the default printer X Dialog When this check box is checked on the Print dialog box is displayed before setting the report to printer In this dialog box you can setup your printer set the print range the number of copies etc The Exit button is used to close this window 3 8 RECOMMENDED MODE
61. lectronic key is supplied with the software and should be attached to the parallel printer interface If a printer is already attached to the interface the key should be attached to the interface first and the printer should be attached to the key The key is transparent to the printer and does not influence printing If the program fails to find the key it displays a message The hardware protection key or security driver needs to be installed 2 2 TECHNICAL SUPPORT DREAM software was developed by the VibroTek Ltd from St Petersburg Russia If you have any questions comments sugges tions or need help please call 7 812 327 5563 or fax 7 812 324 6547 e mail vibro vast spb su or write Vibrotek Ltd 140 Stachek pr St Petersburg 198207 RUSSIA G ATTENTION The technical support for DREAM is provided for those customers who filled and sent the registration form to the above address When you apply for the support make sure that you know your registration number that will be sent to you after receiving the registration form 2 3 USER INTERFACE DREAM for Sentinel is a Windows application and we assume you are familiar with the Microsoft Windows operating system DREAM has the standard Windows interface and we will focus on the peculiarities of DREAM Once you started the DREAM program you see the main window see Fig 2 14 Choose the Open command from the DataBase menu The program had read the Senti
62. lso enables you to print the contents of all windows directly by your printer from the DREAM program spectra Display Measurement Point Analysis 4 File View Options Window Help Cd A Print Preview Print 117 Printer Setup 110 0 100 200 Copies the active window contents and puts it the Clipboard Copies the active window contents and puts it on the Clipboard The corresponding button in the speed bar is Eel Afterwards you can paste the contents of the clipboard to any application e g MS Word text editor include it in the documents and print Copies active window contents into file The corresponding button in the speed bar is The file is saved in the Windows Bitmap format and can be edited and printed by graphic editors e g Paintbrush or imported to the most text editors By the Copy to command the Copy Image to File dialog box is displayed Copy Image to File File Hame Directories 107 new 2 c Em 107 new dll 25 dreamdb C newdb Save File as Type Drives Bitmap files s E c system a HBBEEBNE In this dialog box you can choose the directory and file name for copying a picture Print Preview Displays the page layout for printing The corresponding button in the speed bar is 8 By the Print Preview command from the Graphs menu the corresponding window is displayed l Fig 4 21 spec
63. many times they are used It can be useful for example if you want to know whether you need the bearing of this type Or if you configured an improper bearing and that caused wrong diagnostics you need to know in which points it is used delete the data and reconfigure these points Only then you can delete the improper bearing When to find points with the improper configured bearing you use the Measurement Configuration report select the highest level Only then you find all the similar points In another way you can get program message The report is empty Here 1 Select a component type bearing or gearbox 2 Select from the list the bearing gearbox type you are interested in 3 Select a type of the statistic report Confirm your choice by the OK button or escape this dialog by the Cancel button 3 34 Fig 3 43 A PrePrint window with a History report for a measure ment point id Page Operator s Guide DREAM Each report is shown in the special PrePrint program The number ofthe report open is limited only by the resources of your computer PrePrint hist qrp 00m of 1 Bn Bo 54 Bo 52 131 ES X Dialog 1 30 87 1 03 17 PM TEC Turbiniy ceh Fitatelnie FEN Tv Recommendations Mest measurement 08 Fab 1997 Date Time Defect levels Severe i ncipi fy Mat diagnosed Unba
64. n be divided into three main stages preliminary configuration of DREAM and sentinel databases field measurements and condition diagnostics During its operation DREAM uses two databases the one of sentinel where the names of measurement points their hierarchy and corresponding spectra are stored and its own database where DREAM stores additional parameters of the equipment to be diagnosed that it needs as an expert system The configuration process it means to set up all the required parameters of your equipment and measurements should be done in both Sentinel and DREAM databases First of all make sure that all necessary measurement points are configured in the Sentinel database Then before starting DREAM exit Sentinel software start DREAM program choose the Open command from the DataBase menu DREAM will open the database of Sentinel and read all the plants structure After this DREAM will display in its main window the names of all the plants from the Sentinel database DREAM for Sentinel DataBase Measurement Point Spectra Heports Help g Calibration 1 Balancing ville de Montreal To display the names ofthe areas that belong to a plant double click its name The same way you can open the units machines and measurement points 3 2 Operator s Guide DREAM Fig 3 2 The Configu ration command from the Measurement Point menu is used to configure a point in the DREAM database
65. n not be used 2 Displays in the DREAM plant tree only the measurement points configured in DREAM The tree branches that do not contain such points are not present at all 3 The measurement points configuration command is disabled but all other commands including reports diagnostics analysis work as in normal mode Close Exit 4 3 Operator s Guide DREAM The View mode is recommended when you do not need to diagnose new spectra or configure measurement points Closes the database The command is disabled when the database is not opened Closes the database and quits the application THE MEASUREMENT POINT MENU Fig 4 2 The Measurement Point menu of the DREAM software This menu contains several commands to work with measurement points to configure measurement points and edit configuration data delete copy paste enter and retrieve information about the setup condition of measurement points and last maintenance date also it enable you to make manual diagnostics the Analysis command DREAM for Sentinel DataBase 10719101 Spectra Reports Help Configuration Copy Configuration Ctrl C Delete Data Ctri Del Setup Maintenance Last Results Analysis Below you can see a detailed description of each command from this menu 4 3 1 CONFIGURATION The Configuration command from the Measurement Point menu is used to configure set up a point in the DREAM database This command display
66. ndred For DREAM these two spectra are as one measurement and it will identify this measurement by the date of the leading spectrum So for diagnostics DREAM needs leading and required spectra to be measured additional spectra may be used to refine some types of defects but not required Leading spectra are used to identify the measurement and only the date of leading spectrum is presented in all reports and lists Click this button to close the window This command is used to display the information about the maintenance and repair works that have been done for this very measurement point and enables the operator to enter new dates of maintenance This information can be vital if you would like to 4 10 Fig 4 11 The Mainte nance Date dialog Old Last lal Fig 4 12 The Set Maintenance Date dialog box Operator s Guide DREAM compare spectra from different dates The thing is that sometimes during maintenance the vibration pattern on the machine may change and the spectra measured before and after maintenance may be not compatible By this command the Maintenance Date dialog box is displayed Maintenance Date Old 107 7 95 Here The last previously entered maintenance date An input line where you can enter the last maintenance date If you enter a maintenance date in this line next time you call this command this date will be displayed in the Old text box The following controls are used t
67. ne C Run Hinimized Ifyou are installing the software from floppy drive b type in b setup above Now you will see the Welcome window ofthe installation program for Sentinel 2 1 Installation Welcome This installation program will install DREAM for Sentinel 2 1 Press the button to start the installation can press the Cancel button now if you do not want to install DREAM Far Sentinel 7 1 at this time DREAM Chapter 2 Starting Up 2 3 Fig 24 i tear ee meee er Ea The Select Destina tion Directory dialog Select Destination Directory Please select the directory where DREAM for Sentinel 2 1 files are to be installed Free Disk Space After Install is based on your current selection of files to install negative number indicates that there is not enough disk space to install the application to the specified drive CADREAMFS Current Free Disk Space Sr a8 Free Disk Space After Install 48311 k Cancel The dialog provides you with selection of a directory to copy the software files To select another directory than the displayed click the Browsebutton It displays a dialog to explore your disks for path to a directory to be created Fig 2 5 RTEA The Select Sentinel Directory dialog Select Sentinel Directory Please select the director where Sentinel program files was installed Browse Current Free Disk Space If no path
68. ned shaft vibration Misalignment of the bearing Wear of the bearing 2 40 Shocks in the bearing Defects of lubrication Coupling defect Notidentified changes in vibration ef 60 Display diagnosis by the envelope spectrum Results of diagnostic you can easily require in the main window of DREAM To do it select the measurement point and double click it with the left mouse button 3 26 Operator s Guide DREAM ae ae tree Dy nostics results box Defect with the list of defects tee Probability Revolution around outer race Do p 7j 2 Nonuniform radial tension of bearing 3 Misalignment of outer race 4 Wear of outerrace 5 Cavities on outer race _6 Wear of innerrace BU Severe 80 7 Cavities on innerrace 8 Wear of balls _9 Cavities spalling on rolling elements 13 Severe 0X 10 Defects on several bearing MiSipore o S 12 Defects _of lubrication doo o o Nest measurement 10 Map 1956 Recommendations Heplace bearing 1 wf K You can get this box also by the Last Results command from the Measurement Point menu 3 9 2 EXPERTISE Click the Expertise button in the Detailed Diagnostics dialog box to get the expert estimation ofthe spectrum recommendations and all defects and their symptoms together with the warnings and comments By this command the following window will be dis played estimation of the RECOMMENDATIONS
69. nel database and shows the plant tree created with the Sentinel software as well as all the DREAM menus DREAM Chapter 2 Starting Up 2 9 Fig 2 14 DREAM for Sentinel The main window of DataBase Measurement Point Spectra Reports Help fa Calibration 1 the DREAM software after using the Open command 1 Balancing vite de Ji Fitration Atwater Jl D shumiciticateurs Jl To select a node in the plant tree click it with a left mouse button To display the next level in the plant hierarchy double click the closed door near a node in the plant tree To collapse a branch in the tree double click an opened door with the left mouse button The measurement points have different icons in the plant tree To display the condition of the measurement point double click its icon with the left mouse button Fig 2 15 DREAM for Sentinel DataBase hk The main window of Defects the DREAM software E eer epus with the Diagnostics otter acs Caviies onouteriace Results dialog box ee ee 70 2 7 Cavities oninnerace 8 Wear of balls or rollers ee Balar Level 9 Cavities spalling on rolling elements 13 Z Severe 10 Defects on several bearing surfaces Lo TW Slip face 12 Defects of lubrication Next measurement 10 May 1996 Recommendations Replace bearing 2
70. ng designation bearing type and the bearing dimensions Click the Select button and the Bearing Selection dialog box will appear Choose a Bearing Ce Doe PENNE D sieis 50047 SU 7805 vaz 40 000 0 000 65 000 90 000 110 000 Ba 000 120 000 BD 000 20 000 26 000 90 000 150 000 180 000 190 000 240 000 180 000 260 000 150 000 46 000 57 000 15 080 25 400 30 160 31 750 41 250 24 000 42 960 26 990 6 000 6 000 0 000 0 000 0 000 0 000 0 000 0 000 0 000 36 000 12 000 12 000 4 In this dialog box you have to choose designation identifier under which the bearings are listed in the specification documents ofthe manufacturer where all the technical data of the bearings are specified that is installed in this measurement point There are variants You can choose the designation from the list box where all the bearings that have been entered once in any measure ment point are listed or import one from the bearing library that is supplied together with the software and contains data of about 5000 bearings or create a new designation DREAM Fig 3 8 The Bearing Import dialog box lists several thousands of bearing s designa tions Chapter 3 Operating the DREAM Program 3 5 choose the designation from the database the bearings that were entered once in a measurement point click the desired designation name from
71. ng of the machine operation Wear of the outer race This bearing defect appears during machine operation and results in pitting of a part of the outer race When the rolling elements roll through this wear zones the friction coefficient increases but the shock pulses do not occur on the outer race This defect as a rule appears as one of the first in the bearings with a fixed outer race and develops relatively slowly Cavities on the outer race This bearing defect is the result of the race wear the appearance of cracks the impact loads during maintenance transportation and so on It is characterized by the appearance of shock pulses from the rolling elements impacts on the outer race in the defect zone and by the quick development of the defect level The defect can appear in any stage of bearing operation and significantly decreases its service life Wear of the inner race This bearing defect appears during machine operation resulting in pitting of a part of the inner race When the rolling elements roll through this wear zones the friction coefficient increases but the shock pulses do not occur on the inner race The defect develops relatively slowly Cavities on the inner race This bearing defect is the result of the race wear the appearance of cracks the impact loads during maintenance transportation and so on It is characterized by the appearance of shock pulses from the rolling elements impacts on the inner race in the
72. nt colors It contains also the list of enumerated defects that depend on the measurement point type EM eno NM 4 6 THE HELP MENU This menu enable you to display the information about application s features by means of the standard Windows Help Fig 4 50 DREAM for Sentinel 141 The Help menu DataBase Measurement Point Spectra Reports 1 Contents 1 Calibration Demo Balancing ville de Montreal This menu contains two command Contents Starts the Help system and displays the Help table of contents About When you choose theAboutcommand the dialog box appears with copyright and version information DREAM 4 7 FLOATING MENU Fig 4 51 The DREAM main window with the additional menu which supplies you the main commands Chapter 4 Menu Description 4 41 In the DREAM main window you can access the additional menu which contains the main commands needed for operation It is called by the right mouse button DREAM for Sentinel DataBase Measurement Point Spectra Heports Help g Calibration g Balancing vite de Montr al Filtration amp twater Deshumiditicateurs g Foste de chlore Compresseurs Diagnose The floating menu is the most convenient way to work with the plant tree This menu contains commands from other two menus Measure ment Point and Spectra The commands from this menu are applied to the selected node in the plant tre
73. nt point Click the OK button to delete date or the Cancel button to disable changes This menu contains the Diagnose command only DREAM for Sentinel jw DataBase Measurement Point ilaste Reports Help M vue de Montr al Diagnose Filtration amp twater D shumidificateurs Jl Jl i The command is used to diagnose spectra for selected measurement point and store results of diagnostics in the DREAM database E Oo UMEN By this command the Diagnose New Spectra dialog box is displayed Fig 4 32 In the Diag Diagnose new spectra D shumidificateurs nose New Spectra Machines Measurement Points Hew Spectra dialog box you can 4 18 96 6 43 16 PH choose spectrum PROCEDE2 5 9 96 4 57 10 PM from the Sentinel database for process ing with DREAM X History In this dialog box you can choose spectrum from the Sentinel database for processing with DREAM It contains three lists Machine Measurement point and Spec trum Dependent on what node you selected in the plant tree you can select the machine measurement point from this machine and corresponding spectra If you selected a unit you can make choice in all lists if you had selected a measurement point the first two lists are disabled The spectra are listed by the time and date of measurement the time and date of the leading spectrum are presented
74. o operate this dialog box Click this button to call the calendar for choosing the date of maintenance Click this button to apply changes and close this dialog box Click this button to disable changes and close this dialog box Once you clicked the button the Set Maintenance Date dialog box will be displayed Set Maintenance Date aa October 1996 rr 1 2 3 4 5 b n g 10 11 12 13 14 15 16 17 18 19 20 2 22 23 24 25 26 2 20 29 30 31 Here to select a date within current month just click it with the right mouse button To change the month and the year use the following controls Click this button to advance one year forward Click this button to advance one month forward DREAM 14 e 4 3 4 LAST RESULTS Fig 4 13 The Diagnostics Results dialog box with the list of defects Defects Date of the Next Measurement Chapter 4 Menu Description 4 11 Click this button to advance one month backward Click this button to advance one year backward Click this button to apply changes and close this dialog box Click this button to disable changes and close this dialog box This command is used to display the information about the current condition of the measurement point or the results of the last diagnostics This command can also be accessed through just double clicking the measurement point node in the main window of the DREAM software This command calls the Diagnosti
75. ommendations Mest measurement 08 Fab 1997 Date Time Defect levels Severe zm Incipient var Mat diagnosed Unbalanced rotor Dh Shaft icouplina wobbling Defects of support structure Dh Selfsustained shaft vibration 95 Misalignment of the bearing The following controls are used in this window The Page input box to set the page number for display You can use arrows to scroll through a report The Zoom input box is used to setup displaying You can use the arrows advance this control By the arrows you can change zooming in 1096 intervals 4 30 X Dialog Fig 4 38 The Re ports menu Operator s Guide DREAM Click this button to set zoom to 100 Click this button to fit the whole page in the window Scales the editing view to see the width of the page The Load button is used to open your previously saved report to view or print it The standard extension for the report files is QRP The program normally saves only one last report of each kind on disk The Save button is used to save a report on disk The standard extension for the report files is QRP The program normally saves only one last report of each kind on disk so to be able to open and print reports later you have to save them manually Click this button to print a report on the default printer When this check box is checked on the Print dialog box is displayed before setting the report to printer In this
76. onitor the condition of up to ten thousand unit The Manual describes the operation of the application software starting from its installation and up to report generation 1 4 Operator s Guide DREAM Contents REGISTRATION FORM ccccccseccccsscccceececcueceeeeeceeeeeseeaeseeeeeseeeueceuenesenanesenens 1 1 1 3 1 SPECIFICATION 1 6 1 1 WHAT THE DREAM PROGRAM 1 6 1 2 DREAM FEATURES cccccccsececceeserssececeuceensecesesevesevevencseseneuesensnsess 1 6 1 3 SYSTEM REQUIREMENTS cccccseccccseccccecesesecenccesencvessneceusnenseseveves 1 8 2 STARTING 2 1 ZR PN SERES 2 1 220 TECHNICAL SUPPORT 2 4 2 3 USER 2 5 3 OPERATING THE DREAM PROGRAM 3 1 S l CONFIGURATION ute bte sles ena ora eactda 3 1 3 1 1 CONFIGURATION OF THE ROLLING ELEMENT BEARING 3 3 3 1 2 CONFIGURATION OF THE ROLLING ELEMENT BEARING AND GEARBOX re PE bes URS don Russ 3 9 3 1 3 CONFIGURATION OF THE ROLLING ELEMENT BEARING AND SHAFT ICING 3 12 3 1 4 CONFIGURATION OF THE FLUID FILM BEARING 3 12 3 1 5 CONFIGURATION OF THE FLUID FILM BEARING AND GEARBOX a tese tete atari 3 12 3 1
77. plant tree s bearings The report contains the designations of all the bearings which had been configured in the program PrePrint bearn qrp 10 10 96 12 40 40 nemi Seis mm o m 3 sep semp cep 8 3 mm xm smmur SEFE0 1 105 00 160 00 16 70 SEFEO30 150 02 225 00 22 20 SEFE203 17 00 40 00 SEFE309 45 00 100 00 17 50 SEFE322 10 00 240 00 4130 SEFY AE20912F ej cs 12 30 This report presents all designations and specifications of the bearings included in the bearing database These are the bearings that you have on your plant in any measurement points The report can be issued for any selected node of the plant tree in the same form Here are Din diameter of the inner race or the inner raceway Dout diameter of the outer race or the outer raceway if Din was the diameter of the inner raceway DREAM Chapter 4 Menu Description 4 33 Angle contact angle in degrees between the rolling elements and the race Drol diameter of rolling elements Nrol number of rolling elements in the bearing dNrol acceptable variations in the number of rolling elements set by the operator During the analysis of the envelope spectrum the program will correct the number of rolling elements in the limits Nrol dNrol if there is a mistake in the input data If the variations in the number of roll
78. r s Guide DREAM Here are listed all types of defects with actual and default levels The defect levels are presented in the percentage of modulation And the level for the defect of lubrication is in dB To change values select the type of defect and type a new value in the input line under the list This way you can edit all the defect levels To restore the default values for all defects click the All default button to set a default lever for a certain defect type select the defect in the list and click the button next to the level input line with the default value You can also change all defect levels by a certain factor To do this type the change factor in percentage in the input box below All Default button and click this button For example to increase all defect levels in two times enter 200 and clickAll Default button Click the Finish button to complete configuration Now DREAM is ready to receive spectra for diagnostics but it has to get spectra from the Sentinel database After a new measurement point was configured or a setup for an old measurement point was significantly changed DREAM displays the following dialog box new Measurement point configured Or measurement setup data essentially changed Reread spectra from Sentinel database Click Yes button to reread new spectra from the Sentinel database or click Noto proceed with configuration If you click No the new spectra will be accessible by DREAM
79. r al Filtration amp twater D shumidifiexteurs RESCTI 19196 5 07 22 TM 10 May 1996 19 96 10 May 1996 arab 5 13 45 PM 10 Way 1996 arab 5 aa d6 PM 10 Way 1996 19196 5 35 25 FM 10 1995 46 DE 3 KAJE 5 40 55 PM 10 Way 1996 GO x Severe Selected recommendations 1 Refine the defect type Replace bearing This report is a subset of the Measurement Points Conditions report in which there are included only the measurement points that have some recommendations Possible recommendations are Refine the defect type it means that a defect is found but the type of it can not be determined actually it 4 38 Fig 4 48 The Error information box Operator s Guide DREAM may be not the defect of a bearing for example but an interference from other units Check the lubrication quality the defect of lubrication was detected that usually results in the increase of the high frequency vibration level Replace the bearing dangerous combination of defects occur This recommendation is given when the system considers that in the next 1 of MTBF 10 of the bearings in such a condition may fail Correct misalignment it means that the mounting defect of the bearing was found the misalignment of inner and outer races This is not a very dangerous defect that leads to the immediate failure of the bearing but it significantly decreases the service life of the bearing Correct nonuniform radi
80. r 4 Menu Description 4 15 The View menu This menu contains view options by which you can display two types of cursors or hide them Fig 4 16 spectra Display Measurement Point B2 Analysis 4 The View menu Eile Bl Graphs Options Window Help Cd Harmonics t ILE armonie Row Display harmonics of the chosen frequency When an option is selected it is marked with a check mark The harmonic cursors appear at the position of the normal cursor The cursor can be placed anywhere in the Analysis window by clicking a mouse in the desired location or it can be moved by cursor keys or by pressing the arrow buttons in the speed bar The position and readouts of a cursor are displayed in the speed bar of the main window If you display a number of spectra the readouts are displayed for all spectra with corresponding colors Harmonics Check on this option to display the harmonic cursor The corresponding button ah will be pressed automatically indicating the chosen option Or you can simply press the button instead of checking the command To hide the cursor check this option one more time Harmonic Row Check on this option to display the harmonic row corresponding to the current cursor position The corresponding button M will be pressed automatically indicating the chosen option Or you can simply press the button instead of check on the command Harmonics cursor can contain any number of harmonics and side bands Harmon
81. r the current ma chine DREAM will present an error message and the electric machine would not be configured Click the Next button 3 14 Operator s Guide DREAM At the Defect levels window Fig 3 10 either confirm levels calculated automatically by DREAM or change them and click the Finish button to complete the configuration 3 1 7 CONFIGURATION OF A BLADED MACHINE PUMP TURBINE Fig 3 17 The spe cialized dialog box for the bladed machine The pumps are considered to be a machine that works with liquids Fans and turbines are the machines that operate with gas Pumps can have a cavitation defect that can be detected by DREAM software To configure a bladed machine At the Configuration dialog box Fig 3 4 choose the Measure ment Point Type Pump Impeller or Fan turbine wheel and click the Next button The Bladed machine setup dialog appears Measurement Point Configuration Type the number of blades on the working wheel and click theNext button At the Frequency parameters window Fig 3 9 put in the Rotation Speed Variation and Max Variation and click the Next button At the Defect levels window Fig 3 10 either confirm levels calculated automatically by DREAM or change them and click the Finish button to complete the configuration DREAM 3 2 SETTING UP MEASUREMENTS Fig 3 18 The Mea surement Setups command from the Heports menu is used to issue the list of setting
82. ram History A report file where all diagnostics results are presented The recommendations are given as a result ofthe last diagnostic measurement The file is printed on the screen and you can browse it in the file viewer Max The maximum value of variations in the input data for Frot 96 with which the program will still identify the defect type but will give a Warning signal to the operator DREAM Appendixes Glossary 5 7 Not identified defect unidentified defect A defect that differs from the 12 types that the program can identify In this case the program will give only its depth and the recommendation to replace the bearing The operator can 1 Check whether the processed spectrum belongs to the chosen measurement point 2 Check the data in the measurement point 3 Check the data in the bearing s designation 4 Make a new measurement Nrol The number of rolling elements in the bearing Service life The period in months during which the bearing is intended to work without replacement mean time before failure
83. red by means of the Statistics command from the Report menu Then you have to delete all data from them by the Delete Data command from the Measurement Point menu Only after that you can delete an improper type in the gearbox configuration window Here you have to put in all the frequency parameters First axis rotation frequency Rotation frequency variation and may be Maximum Variation more detailed description of these param DREAM Chapter 3 Operating the DREAM Program 3 11 eters you can get in the previous section 3 1 1 Configuration of the Rolling Element Bearing Click the Nextbutton to confirm all the inputted data The last section of the Measurement Point Configuration the defect levels window should appear The last configuration step is the same as for the rolling element bearing Refer to it This way you can configure the DREAM database for all the measurement points that were created in the Sentinel software di In vi Measurement Point Configuration lalog Operator pane oo DeectTwe Level Def levels calculated Db automatically by Coupling shaft wobbling 25 20 25 20 DREAM or change 2 Small gear wheel detects 3 Large gear wheel defects them according to his 4 Small gearing defects experience Large gearing defects Defects on another axis Wear of outer race Coupling shaft wobbling 29 Coa 0 3 12 Operator s Guide DREAM 3 1 3 CONFIGURATION OF THE ROLLING
84. rollers Nonuniform radial tension of bearing Cavities spalling on rolling elements Misalignment of outer race Defects on several bearing surfaces wear of outer race Slip of race Cavities on outer race 134 521 Defects Wear of inner race Matidentified changes in vibration Cavities on inner race The Diagnosis dialog box contains three fields You can change the size and shape of each window by dragging field separators The first window presented a spectrum In the second window all lines found in the spectrum are presented and classified by their origin For example is the rotation speed and Finare the ball passing frequencies on outer and inner races etc n the third window you can see all the defects found in the bearing 3 24 Operator s Guide DREAM When you check on any check boxes for frequencies in the second field the corresponding lines are marked in the spectrum by red lines If you check on any check box near the defect you will see reasons for diagnosis in the first window you will see the lines by which the defect had been found the lines will be marked by red lines in the second window these lines will been checked on Fig 3 30 To finda line in the spectrum Diagnosis check on the check Envelope fEnscHistony rect feros boxes of the corre sponding frequency 100 200 3813Hz 6 C 180 37Hz 6 2Fout 2 S026Hz13 F
85. rolling elements Variation in number of Drol mm rolling elem Dinral X ona 4 4 X Cancel lt lt Prev gt gt e m m e Fig 4 5 Bearing Selection dialog box is used to work with the data base of bearings designations Operator s Guide DREAM The second section displays information about the bearing desig nation and has the following controls Click this button to choose a designation from the database or enter a new one Click this button to disable changes and close this dialog box Click this button to apply changes and go to the previous section of this dialog Click this button to apply changes and advance to the next section of this dialog box When you click the Select button the Choose a Bearing dialog box will be displayed on the screen 40 000 15 080 0000 0 000 aa 000 90 000 110 000 Ba 000 120 000 60 000 150 000 180 000 190 000 240 000 180 000 260 000 150 000 25 400 30 160 31 750 41 280 24 000 42 960 26 990 0 000 0 000 0 000 0 000 0 000 0 000 36 000 20 000 26 000 50042 50 7805 46 000 6 000 S 6 000 12 000 12 000 co This dialog box lists all the bearings designations that were used for any measurement points previously To select a bearing click a desired row To change a bearing parameters simply click a parameter to be changes and enter the new value The followin
86. s px gearbox db results val strings val gearbox px roll db turbin db gearbox val roll px turbin px gearbox x02 rtyp_10 db turbin val gearbox y02 rtyp_10 px 5 2 Operator s Guide DREAM GLOSSARY Angle The contact angle in degrees between the rolling elements and the race Data Variations DV During machine operation some variations can appear in process parameters for example in rotation frequency fr There can also be some mistakes in data such as in the number of rolling elements Nrol or in the dimensions of bearing elements Defect Level The danger of a defect depends on the stage of its development Each defect according to the stage of its development can be considered as an incipient a medium or severe defect The incipient level means that the defect is detected and identified but in normal operating conditions it cannot lead to a failure in a predictable period which is considered to be about 2096 of its specified service life The severe level means that the defect is in such a state of development that there is no possibility to ensure its work for a long period without failure The bearing must be either replaced or if its operation is prolonged the period between measure ments must be reduced to 1 596 of its specified service life Under these conditions the operation of the bearing can be prolonged up to the moment of appearance of an automatic indication on danger to fail Defect type The follo
87. s the Measurement Point Configuration dialog box DREAM Chapter 4 Menu Description 4 3 Fig 4 3 Measurement Point Configuration Measurement Point Configuration dialog box Is used to set up Measurement Point a point in the DREAM database Bremen E control period days This dialog box contains three sections that can be switched by the Next and Prev buttons The first section have the following controls Measurement Point Type list box where you have to choose one of the measurement point types from the list Click the button to open the list Maximal Control Period An input box Enter the period in days that will be an interval between measurements for a measurement point that has no defects according to the last diagnostic results For rolling element bearings we recommend to enter 2096 of MTBF Click this button to disable changes and close this dialog box Next gt gt Click this button to apply changes advance the next section of the dialog box The following for example is the rolling element bearing configu ration Click the Next button to advance to the next section Fig 4 4 The second section of the Measurement Dec gration SKFED07 Point Configuration dialog is used to Diameter of inner race Dun 35 000 Contact angle Angl select a bearing mm degrees designation Diameter of outer race O out 2 000 Number of ralling mm elements Mral Diameter of
88. s to be done for the unit or give a non failure operation period prediction Then DREAM will automatically follow up the conditions of your equipment and include in the list only the measurement points for which the condition prediction is expired according to the day you chosen In the Meas Date column you can see the expiry date of the condition prediction If this point have not been measured previ ously Not determined will be presented in this column Once you ve got the list of measurement points to be measured you can go to Sentinel and form a corresponding route and download it to the Type 2526 data collector 3 20 3 4 COLLECTING Operator s Guide DREAM AND PROCESSING DATA Fig 3 25 The Diag nose command from the Spectra menu Fig 3 26 In the Diagnose New Spec tra dialog box you can choose a spec trum from the Senti nel database for processing with DREAM The vibration data are collected by the Type 2526 data collector according to the routes formed and loaded through the Sentinel software After measurements unload the routes from the data collector into the Sentinel database process data by DREAM exit Sentinel and start DREAM In the plant tree choose unit machine or point for data processing and select the Diagnose command from the Spectra menu DREAM for Sentinel DataBase Measurement Point Reports Help Ji vue de Mantr al Diagnose Filtration amp twater i D
89. s to set up measurements in the Sentinel database Fig 3 19 The Setup command from the floating menu pre sents the Measure ment Setup informa tion box for a single measurement point only Chapter 3 Operating the DREAM Program 3 15 According to the configuration data of measurement points DREAM will require to set up the measurements in the appropriate way This should be done in the Sentinel database Preliminarily you can issue a list of the measurement setups required for DREAM diagnostics on all measurement points have a look at them and set up measurements for the points in Sentinel according to this list For that purpose select in the DREAM software a machine or a unit to which the measurement points to be configured belong and use the Measurement Setups command from the Reports menu DREAM for Sentinel 141 DataBase Measurement Point Spectra Statistics Points Configuration B Predprijatie 2 Measurement Setups Points to Be Measured g TEC 8 Masenerga Conditions g Predprijatie 4 Hecommendations g g There is also Setup command in Measurement Point menu and in the floating menu as well This command presents the Measurement Setup information box for a single measurement point only Measurement Setups Point w Rotation Frequency Hz 50 Status 1000 7080 8910 Fig 3 20 The Mea surement Setup wit
90. splaying them Automatic identification of 12 types of unit defects with an indication of their levels incipient medium or severe Automatic prediction of the unit s non failure operation until the next measurement the time period between measurements can be up to 2096 of its MTBF Practically unlimited number of units in configuration which the customer can make by himself The configuration can be corrected or added very simply Automatic determination of recommended danger defect levels and the ability to adjust them in compliance with the collected data Automatic speed compensation and correction of the number of rolling elements during data processing Storage of the results of intermittent vibration measurements and an unlimited number of successive measurements for each of the units The simplicity of diagnostic measurements and the automatic test of the compatibility of the current spectrum and previous ones Advanced search and output facilities A detailed diagnostic process with the ability to display the results of different stages of the process on the screen Context sensitive helps DREAM Chapter 1 Specification 1 7 Output and printing of the following data the list of the bearings designations with their specifica tion data the list of the analyzer setup during the measurements the history of diagnostic data of the chosen unit the list of the units condition with an indication of mos
91. surfaces Slip of race Defects of lubrication Notidentified changes in vibration 80 0 Next Measurement 10 05 56 Recommendations Refine the defect type x R eplace bearing DREAM Chapter 3 Operating the DREAM Program 3 23 In the right part of this dialog box there are three buttons which function is described more detailed in the next sections Done Saves the results of diagnostics in the database and closes Detailed Diagnostics dialog box Details Displays you the spectrum with all lines and the defects found In this mode DREAM can display you the diagnostic symptoms for each defect or recommendation Expertise Displays the expertise of the spectrum including all recommenda tions with reasons for them all the defects with their reasons all warnings or comments in the text form 3 5 1 DETAILS Click the Details button in the Detailed Diagnostics dialog box to get this mode Before you can check on the defect or recommen dation you are interested in from the corresponding list The following window will be displayed Fig 3 29 The results of diagnostics are Diagnosis presented in this Pi Tess window together with the spectrum fre quencies and modu lation indexes of lines found in the envelope spectrum and their identification 0 100 200 3813Hz 6 18037Hz 6 2Fout C 90 26H213 Fout 270 57Hz 6 3Fout Revolution around outer race wear of balls or
92. t severe defect its depth and recommended date of the next measurement the list of recommendations on maintenance of the units the list of units which conditions require diagnostic measurements on the day the operator states 1 1 3 SYSTEM REQUIREMENTS Operator s Guide DREAM Personal Computer IBM PC AT or compatible With the Bruel amp Kjaer Type 7107 M Sentinel software installed 10 Mb on Hard Disk or more for the program and the database Data collector Type 2526 The DREAM Application Software is supplied on floppy disks The software is protected by an electronic key which must be attached to the parallel port The key is supplied with the software as well as the key driver to work with Windows the Security software DREAM 2 STARTING UP 2 1 INSTALLATION Note Chapter 2 Starting Up 2 1 DREAM for Sentinel is a Windows software that works with the Bruel amp Kjaer Type 7107 Sentinel database To install and operate DREAM you must be familiar with the basic operation of Microsoft Windows and have installed Sentinel software of version M or higher The DREAM application software is supplied on distribution diskettes t have to be installed with an automated installation program that s called Setup The DREAM distribution diskettes contains Q DREAM application software with an installation program for the SETUP EXE Borland Database Engine softwar
93. t do not require autospectra for diagnostics e g for rolling element bearings Displays diagnosis by the autospectra history This command equals to the Dir History button in the speed bar This command is disabled for the measurement points that do not require autospectra for diagnostics e g for the rolling element bearings Closes this window DREAM 4 5 THE REPORTS MENU Fig 4 37 A PrePrint window with a History report for a measure ment point Page oom bo 74 Chapter 4 Menu Description 4 29 After diagnostics all the results are stored in the DREAM database and can be retrieved in several types of reports The commands of the Report menu issue reports for the selected node in the plant tree There are only two exceptions The first is the List of Bearings by the Statistics command that is made for all plants and does not depend on the selected node The second is History that can be made only for a selected measurement point When you select a node and issue a report all measurement points that are below this node in the tree hierarchy are included in the report Each report is shown with a special PrePrint program The number ofthe report open is limited only by the resources of your computer PrePrint hist qrp ul Zoom of 1 Bn Bo 54 Bo 52 131 Ell ES pi X Dialog 1 30 87 1 08 17 PM TEC Turbiniy ceh Masnsi Fitatelnie FEN Tv Rec
94. t type Based on NOT IDENTIFIED DEFECT 60 Severe Replace the bearing Based on WEAR OF OUTER RACE 80 Severe Probability 8056 CAVITIES SPALLINGS ON ROLLING ELEMENTS 14 Severe Probability 7025 DETECTED DEFECTS WEAR OF OUTER RACE 8076 Severe Probability 8026 Diagnostic symptoms in the envelope spectrum V arning Diagnostics is based on the harmonics of the rotation speed only they can occur due 10 the defects of other units If the electric mains frequency in your area is bl Hz the diagnostic symptoms may be caused by the electromagnetic interference 5 91 Hz 8096 Frot 11 82 Hz 189 2Frot 17 73 Hz 289 3Frot 23 64 Hz 199 4Frot 29 57 Hz 896 bFrot 35 41 Hz 896 bFrot 41 37 Hz 12 Frot 2Frol 2Fc 53 18 Hz 17 S Frot 59 11 Hz 139 10 65 05 Hz 820 11 3Frol 2Fc 88 55 Hz 820 15 4Frol 2Fc Once you click the Details button before it you can check on defect or recommendation in which you are interested in the corresponding list the following window will be displayed Fig 4 35 The Diag nosis dialog box Evae En E TREE 100 200 3813Hz 6 180 37Hz 6 2Fout C 9026 213 Fout 270 57Hz 6 3Fout Revolution around outer race wear of balls or rollers Nonuniform radial tension of bearing Cavities spalling on rolling elements Misalignment of outer race Defects on several bearing surfaces Wear of outer race Slip o
95. the list the designation will be highlighted and marked by triangle and click the OK button To choose a bearing from the external bearing library that contains 4000 5000 bearings of mainly Soviet and SKF production click the Import button The following dialog box will appear Import a Bearing 4 Designation Din Dro Ang Dnrol b skFl 2X351571 380 00 81000 9000 9000 15 0 skrios2ii7 1700 4000 500 3200 14 0 SKF1066145E 900 25 00 450 4500 12 0 SKFi200 1000 3000 475 1222 3 0 SkKFi200 1000 3000 476 1221 3 0 1200 3200 475 1270 10 0 SKFi2 E 1200 3200 5 00 1264 10 0 SKFi202 1500 3500 556 1254 10 0 SKFi202E 1500 3500 5 56 1254 10 0 skFi2n3 1700 4000 556 11 61 12 0 8 203 1700 4000 600 1181 1 0 SKFi204 2000 4700 6 35 1037 12 0 SKFI20M4E 2000 47 00 714 1115 12 0 eum 20 cw y Bl Use the Mask text box to find the desired designation When you enter the first symbols of the designation the list advances to the corresponding names You can choose one of the bearings by its designation and verify its dimensions Once you click theO Kbutton this bearing designation will be included in the DREAM database and will appear in the list of designations in the Bearing Selection dialog box To create a new designation click the Add button A blank line will appear in the list of bearings Type
96. the parameters of the bearing designation ID in the designation column and all other parameters in corresponding columns Din the diameter of the inner race or the inner raceway Dout the diameter of the outer race or the outer raceway if Din was the diameter of the inner raceway Note if you do not know the diameters of races you can put in the cage diameter as a diameter of both inner and outer race The program actually needs only the cage diameter that is calculated as a mean value of inner and outer race diameters It is also recommended to enter the cage diameter for the thrust bearings 3 6 Fig 3 9 The second section of the Mea surement Point Con figuration dialog Type the Rotation opeed and its Varia tions from measure ment to measurement for this machine Operator s Guide DREAM Angle the contact angle in degrees between the rolling elements and the race Drol the diameter of rolling elements Nrol the number of rolling elements in the bearing dNrol the acceptable variations in the number of rolling elements set by the operator During the analysis ofthe envelope spectrum the program will correct the number of rolling elements in the limits Nrol dNrol if there is a mistake in the input data If the variations in the number of rolling elements exceed the program is not able to identify the type of defect Note Our experience shows that it is rather typical for the bearing manufac
97. tra Display Measurement Point Be 4 The window of the File View Graphs Options Window Help page layout Page 1 Here you can see how the page will be printed This window has the following controls Click these buttons to go from one page to another Click these buttons to display one or facing pages Click this button to display the Print dialog box and print the page Click this button to close page layout window Note The program will automatically fit your picture to the full size of the default paper size of the default printer in Windows To get better results you can use the Printer Setup command to adjust the paper size for better outlook It is also recommended to use the Wide or Landscape paper orientation DREAM Print Fig 4 22 The Print dialog box Printer Setup Fig 4 23 The Print Setup dialog Chapter 4 Menu Description 4 19 Displays the Print dialog box for printing the active window The corresponding button in the speed bar is the Print command from Graphs menu Print dialog box appears Printer Default Printer HP Laserlet 5L PCL on 3Xantan hp LPT1 Print Hange Selection O Pages From Print Quality High s Copies 1 Print to File X Collate Copies In this dialog box you can set up your printer set the print range the number of copies etc Click the OK button to start printing D
98. ts of diagnostics that were made for this measurement point To issue a report choose a node in the plant tree and use the corresponding command from the Reports menu Fig 3 41 The Re 5 DREAM for Sentinel ports menu DataBase Measurement Point Spectra 8 Statistics B Flant Points configuration B Balancing Measurement Setups Points to be measured Conditions Recommendations History vite de Montr al Filtration amp twater Jl D shumiciticateurs Jl DREAM Fig 3 42 The dialog to choose a bearing designation or gear box type for reporting Note Chapter 3 Operating the DREAM Program 3 33 Besides the reports on the selected node you can get the statistics reports on the selected bearing designation or gearbox type They are List of Bearings Measurement Points Conditions Recom mendations To issue a statistic report select the Statistics command from the Report menu It calls the Statistic Report Settings dialog box statistic Report Settings Designation Used l 5 2 351571 0 150198130 0 o o 15021713 150222 28 Lj RR E Configuration suas ONN o Condition EU m B Recommendations seuns O 8 By this dialog box you can choose the component type bearing or gearbox you want to issue a report and type of report as well You can see in this dialog box the list of the bearings gearboxes used and how
99. turers to vary the cage design and thus the number of rollers in the same type of bearing After the bearing designation had been selected and confirmed by the OK button click the Next button and enter the following parameters Measurement Point Configuration Hotation Speed Variation variation X oa Rotation Speed the rotation speed of the bearing can be entered in Hz Variation possible variations in rotation frequency fr from measurement to measurement From the point of the program the variations could be normal set by the operator for example Rotation Speed Variations or maximal The more variations and maximal variations values the less certainty the probability of the exact type of the defect that is displayed by the program and it takes more time to make diagnostics DREAM Fig 3 10 In this dialog box operator can either confirm levels calculated automatically by DREAM or change them according to his experience Chapter 3 Operating the DREAM Program 3 7 If the actual rotation speed is not within variations but within max variations the program identifies the type ofthe defect but gives a warning that the data have variations and while process ing the program has revised them to identify the defect The program generates the same warning if there is a mistake in the number of rolling elements in the limits dNrol Max Variations the maximum value of variations
100. urement Point menu By this command the Spectra Display window is displayed Spectra Display Measurement Point B File View Graphs Options Window Help Eni ERE Analysis NN NNNM S Sem zie 100 18 04 96 18 43 o ee EE The window of the plot program contains the Analysis window where the spectra are displayed the Date that allows you to choose spectra for displaying and analysis the Section that displays the history of certain spectra component s development from measure ment to measurement and 3 D Plot that displays the 3 d surface representation of the spectra development in period from measure ment to measurement The choice of spectra for displaying can be done in the Date window Click the certain date to toggle display hide for a corresponding spectrum You can trend spectra by displaying them all together at the Analysis window The cursor can be placed anywhere in the Analysis window by clicking the mouse button in the desired location or it can be moved by cursor keys or by pressing the I I buttons in the speed bar The position of the cursor and its amplitude readouts are displayed in the speed bar of the main window The color of the spectrum coincides with the color square near the date and color of the cursor readout Fig 3 36 The cursor is controlled in the Analysis window synchronously it moves in the 3D Plot window in the Sec
101. urement point conditions 10 10 96 3 16 21 FM Ville de Montr al Filtration Atwater D shurniditicateurs PROC D Pom Lastmeasurerment Henstrmeazurernent detect level Eecormmendatio Seuere 919 96 4 59 22 10 1996 B3 519196 5 07 22 10 May 1396 41 Severe Recommendations T Replace bearing LL This report presents information about condition of your equipment It is the information when were done the measure ments last time for each measurement point when should be measured it next time on the maximum defect level found in the equipment and lists the recommendations for corrective actions to be done DREAM Chapter 4 Menu Description 4 37 4 5 6 RECOMMENDATIONS The command displays the Select Recommendations dialog box ug ceo esce Recommendations m Recommendation dialog box Corect nonuniform radial tension As a default all recommendations are selected each contains an asterisk in the first column To deselect a recommendation click with a mouse on the asterisk To select it again repeat this action So you can select the needed recommendations Select the desired recommendations and click the OK button The Measurement Point Recommendations report will be displayed Fig 4 47 The Mea PrePrint recom qrp surement Point Rec ommendations report Measurement point recommendations 10110796 4 31 50 FM Ville de Mont
102. ursor can be File View Graphs Options Window Help used to find side bands for certain spectrum compo nents Fig 3 38 Harmonic Spectra Display Measurement Point Analysis Row cursor can be File View Graphs Options Window Help used to find harmonic TIENS rows in the spectrum Se EA You can display the window with all the bearing frequencies To do so use the right mouse button Click it in the Analysis window and the list box of bearing frequencies will be displayed Fig 3 39 The list box Spectra Display Measurement Point Analysis presents all the char File View Graphs Options Window Help acteristic frequencies MIRAE of a bearing MORSE OOO eok The rotating rate of inner race 5 90 The rotating rate of the cage 2 61 The frequency of rollers contacts 15 32 The frequency of rotation of rollers on outer race 36 57 WI The frequency of rotation of rollers on inner race 46 03 100 200 0 3 30 Fig 3 40 The Graphs menu for printing and copying graphics Attention Operator s Guide DREAM To move cursor to the frequency position in the Analysis window click the frequency you are interested in To create a report in a standard text editor with any pictures from the Spectra Display window you can copy into clipboard contents of any window Two commands from the Graphs menu can be used to do it These are Copy and Copy to commands spectra Display Measurement Point B2 4
103. ution around outer race i EH Monuniform radial tension of bearing Misalignment of outer race Wear af outer race Cavities on auter race Wear af Inner race Cavities an inner race j Revolution around outer race ra X ona The last section displays information on the default calculated by the program and actual levels for severe defects The actual levels are presented in the Level column and the default in the Default 4 8 ps Lal All Default X Cancel lt lt Prey Finish cn a pi i ER 4 3 2 SETUP Fig 4 9 The Measurement Setup information box with the Envelope spectrum section visible Operator s Guide DREAM column To change level for a particular defect select it and use the following controls Type a new level in this input box Click this button to restore the default level for the selected defect Click this button to set default levels multiplied by the below percentage to all defect types in the list Click this button to disable changes and close this dialog box Click this button to apply changes and go to the previous section of this dialog Click this button to apply changes and close this dialog box For the different types of the measurement point the program calls the different configuration dialog boxes on the second stage of configuration On the other stages of configuration the dialog boxes will be the same as for the example above on the rolling el
104. wing types of defects are identified for the rolling element bearing Revolution around outer race Nonuniform radial tension of bearing Misalignment of outer race Wear of outer race Cavities on outer race Wear of inner race Cavities on inner race Wear of balls rollers or cage N NN BW N Cavities spallings on balls and rollers 10 Complex defect on two or more roll surfaces 11 Slip of race 12 Defects of lubrication DREAM Appendixes Glossary 5 3 Each type of defect is rated into four levels according to the stage of its development 1 No defects 2 Incipient defect 3 Medium defect 4 Severe defect The exceptions are made for defect types such as Revolution around outer race and Slip ofrace which are united into one group Defects of lubrication is divided into two levels medium and severe The program generates an automatic indication of failure danger only after setting up the levels for severe defects The levels are set up for each type of defect by the customer himself according to the recommendations in the software instructions and the experience in the program operation Revolution around the outer race The revolution around the outer race is characterized by appearance of dynamic forces applied to the outer race by the rotor or shaft These forces revolve around the outer race synchronously with the rotor or shaft rotation So it is not a defect
105. wn list box of the Measurement Point Type dialog box Measurement Paint Type Induction motor Induction motor Synchronous machine Pump impeller Fan turbine wheel Rolling bearing and shaft line Rolling element bearing Rolling bearing and gearbox Fluid film bearing i The list of the diagnosed units will be consequently enlarged by the DREAM designers Once you select the Measurement Point Type and type or confirm Maximum Control Period click the Next button 3 1 1 CONFIGURATION OF THE ROLLING ELEMENT BEARING To configure a rolling element bearing choose this type in the Measurement Point Setup dialog box Fig 3 5 The Rolling Element Bearing type selected in the Mea surement Point Con figuration dialog box Measurement Point hi aximum Control Period days 3 4 Fig 3 6 Click the Select button which is used to go to the Bearing Selection Fig 3 7 The Bearing Selection dialog box with designations from the DREAM database Operator s Guide DREAM Enter the Maximal control period click the Next button and the new section will appear Measurement Point Configuration Designation Diameter of inner race Din Contact angle Angl degrees Diameter of outer race O out Number of rolling mm elements Mral Variation in number of rolling elem Dinral Diameter of rolling elements Drol mm X oa This dialog box is used to display the beari

Diagnostic Rolling Element Analysis Module (DREAM)

Contents

Download Pdf Manuals

Related Search

Related Contents