DLI Watchman ST-101TM Vibration Screening Tool

The ST-101 in a PdM Program

The DLI Watchman ST-101 is designed as a simple vibration screening and diagnostic tool. Where a complete predictive maintenance program is operating using advanced data collectors, it might seem like the ST-101 would be of no value, but this is far from the case. There are many applications where the ST-101 can enhance and extend a conventional predictive maintenance program, and in some cases even do a better job than conventional data collectors and analyzers.

The ST-101 as a Screening Tool

Using conventional vibration data collectors, a certain amount of overhead is involved in preparing the machine for measurements, determining the mechanical features of the machine, setting up the measurement locations in the database, creating the setup files in the expert system, and so forth. Once all the setup work is done, the actual data collection usually involves members of the maintenance staff, who often have more work than they can handle. This effort of course is well justified for critical machines, but becomes less justified on non-critical machinery in the plant. The ST-101 can help make more effective use of the maintenance staff members time. Screening machinery to determine what to include in the program When a predictive maintenance program is started, the machines to be included in the program must be selected. Machines critical to the operation, machines with a history of maintenance problems, and machines requiring a lot of calendar-based maintenance are usually the first choices to include in a program. Beyond this, there may be many machines that are basically unknowns, but they are too numerous to include every one in the predictive maintenance program. The ST-101 can be used to quickly screen these unknown machines to determine which ones have potential problems which could lead to failure. The only information required to provide a good reading with the ST-101 is the machine speed, and the magnetically mounted accelerometer can take rapid measurements without the need to attach accelerometer mounting disks. In this way, the machines most likely to fail can be identified and included in the full scale predictive maintenance program. This increases the effectiveness of the program by concentrating monitoring on machines most likely to fail, and reduces the chances of failure of the machines that arent routinely monitored. Screening machinery periodically that is not included in the program Some plants have so many machines that they cannot all be included in a conventional monitoring program. The ST-101 can extend the effectiveness of the monitoring program by allowing machinery operators or plant mechanics to periodically test the machines in their area, and notify the predictive maintenance program staff of any increases in vibration levels which would

Literature Number PM-AN104

APPLICATION NOTE

indicate the possibility of failure. When a machine has been flagged, repair action can be taken immediately if warranted, or the machine monitored using conventional technology. This increases the effectiveness and coverage of the predictive maintenance program, and reduces the chance of unexpected failures. Machinery operators and mechanics can be trained to use the ST101 in a short period of time. Monitoring problem machines The conventional predictive maintenance measurements may show problems with a machine, but because of production demands or other requirements, that machine cant be removed from service for repair. The ST-101 can be used on a more frequent basis to detect additional deterioration that would call for immediate repairs. Since measurements with the ST-101 require only a few minutes, and can easily be interpreted on the spot, a machine can be monitored on a daily or even hourly basis to squeeze the maximum operating life from a critical machine before shutting it down.

Applications Where the ST-101 Can Be the First Choice

For some applications, the ST-101 will actually out perform conventional predictive maintenance monitoring methods. Some machines have a limited number of faults that can occur and these faults have a clear characteristic pattern on the ST-101. Monitoring Machine Tool Spindles Many machine tools have a simple spindle arrangement driving some kind of cutter or grind stone. These spindles may be directly driven from a motor, Axial or may be belt driven. Spindles of this type basically fail because the machine tool wears and becomes out of balance, or the bearings fail. Either of these Rolling Element Cutting Tool Bearings failures can result in poor product quality and rejected materials. It is important to monitor these spindles Motor frequently to detect problems before product quality suffers. Using the ST-101, a spindle can be measured in just a couple minutes, with the results instantly available. Bearing Machine Tool Spindle deterioration, tool imbalance and belt problems all have distinct patterns on the ST-101, so the machine operator will know its time to change the tool, or time to call maintenance personnel to replace the bearings or install a new belt. Since the measurements take just a minute or two, readings can be taken on every shift or even more often as conditions warrant. The results are increased product quality and reduced costs from the tool crib.
Vertical Vertical

Monitoring machines with short operating cycles Some machines operate with very short operating cycles that preclude conventional measurements, even when interrupt processing is used (see 8603 ap note). The ST101 requires only a few seconds for a reading to stabilize, so measurements are possible with almost any operating cycle time. The patterns on the ST-101 bargraphs provide good information about the cause of high vibration levels, and by trending the levels, deterioration can be detected. In some cases, the ST-101 may be the only tool that can be used to make measurements. Ranking Complex Machines Some machines are so complex that conventional vibration signatures are impossible to interpret. This includes machines like textile weaving machines, where there are so many moving components located close together that the no sense can be made of the vibration data. Where funds are available to overhaul one out of several machines, and none is clearly worse than the others based on repair history and performance, the broad band readings of the ST-101 can prove useful. Readings can be made under the same operating conditions and at the same locations; the machine with the higher levels is probably the one needing overhaul the most. Deteriorating bearings which may not be otherwise noticeable have a distinct pattern on the ST-101, so this important maintenance item is easily identified.

A Monitoring Program for Machinery Operators and Mechanics

Periodic measurements made by plant mechanics and machinery operators can greatly enhance the scope of a predictive maintenance program, and extend coverage to machines that would otherwise be overlooked. A few guidelines can help ensure that proper measurements are taken by personnel with little background or training. Use magnetic disks to mark the test locations As with any vibration monitoring program, it is essential that test measurements be taken in the same location each time to allow trending of the test results. Measurements will be taken in the same location every time if a magnetic transducer attachment pad is installed at each test location. Establish repeatable test conditions Measurements must be made under consistent test conditions to allowing meaningful trending of results. It is important to document the test conditions for each machine, and to have this information in the hands of the person taking the measurements. A log sheet can be used to identify measurement locations and test conditions, and to record vibration levels for each survey. A sample log sheet is available on the web site. Train the personnel using the ST-101 Operation of the ST-101 is simple, and can be learned with a short training session. The magnetically mounted accelerometer is placed on the test location, the operating speed selected, and the results read out after a few seconds of stabilizing. A diagram of the ST-101 controls is shown on the next page. Red and green LED bargraghs indicate acceptable vibration levels, and the pattern on the bargraphs represents the problem causing high vibration levels. The pattern can be compared to a pocket reference guide to determine what type of fault the machine has. The Pocket Guide and the Operators Manual are available on the web site. A variety of application notes are also available on the web site to aid in using the ST-101. Some familiarity with machinery is helpful when using the ST-101. Machinery operators and plant mechanics will have no trouble effectively using the ST-101.

Basic Operation
LOW
128 122 116 110 104 98 92 86

MID

148 142 136 130 124 118 112 106

HIGH
60 Hz 50 Hz Englis h Metric
VdB re 10-8m / VdB res10-9m / s

Select 50 or 60 Hz operation by pressing and holding 900 and 1800 RPM buttons until power frequency is toggled. Select US or metric units by pressing and holding 1200 and 1800 RPM buttons until units are toggled between US CAL (English) and ISO CAL (metric).

DLI WATCHMAN

ST-101

Vibration Screening Tool

Read the Quick-Trend number here, or the vibration units selected by the bottom row of switches.

RPM
Select the nominal operating speed of the machine here. 60 Hz operating speeds are in yellow, 50 Hz operating speeds are in white. Select the local power line frequency as discussed above. Press the POWER switch to turn the unit on. It will turn itself off after a few minutes. Press the button to display desired units in the 4 digit display above. US or metric units are selected as shown above.

900 750 Power

1200 1000

1800 1500

3600 3000

Disp

Velocity

Accel

Display

US Unit ISO Units

Displacement mils rms mm rms

Velocity IPS rms mm/s rms

Acceleration g rms m/s2 rms

The ST-101 is simple to use. Turn it on, select the machine speed, and make the measurements. Satisfactory vibration levels are shown by green LED bargraphs. Red LED bargraphs indicate high vibration levels that should be investigated. Determining that a problem exists is only part of the problem. The pattern on the ST101 bargraphs indicates the most likely cause of the unacceptable vibration levels so that repairs can be planned. For example, an out of balance pump will require different tools and personnel to correct than a deteriorated motor bearing. A simple pocket guide quickly allows untrained personnel to determine the machinery condition resulting in unacceptable vibration levels.
DLI Engineering 253 Winslow Way W. Bainbridge Island, WA 98110 800-654-2844 206-842-7656
Literature Number PM-AN104