V-Sensing Lab(A branch of Infrared Engineering & Consultants Ltd.)

V-Sensing Lab CdM Series - SpiderWebWireless Condition Monitoring IoT System for HVAC EquipmentInno Portal Application - Equipment Preventive Maintenance using Internet of Things(Wish List Ref. W-0192)Electrical and Mechanical Services Department (EMSD)

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Project Background• V-Sensing Lab was pleased to apply EMSD Inno Portal program

“Equipment Preventive Maintenance using Internet of Things” (Wish Listref. W-0192) to provide online Condition Monitoring (CdM) and smartsensing system for HVAC equipment.

• Integration of Predictive Maintenance (PdM) strategy and the concept ofIndustrial Internet of Things (IIoT), machines’ health condition data willbe collected, analyzed by the online system and send the real-timecondition / warning signals via LoRa.

• Set up early-stage fault detection algorithm and alarm triggeringprogram based on the vast data collected: maintenance cost $$ plant's asset reliability

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Predictive Maintenance• Vibration Condition Monitoring (VCM) a kind of machinery

Predictive Maintenance (PdM) technique

• Fault(s) abnormal noise, vibration, current usage, temperature

• VCM can identify machine fault(s) & severity by vibration frequenciesand levels respectively

• Complete monitoring solution by integratingmachine temperature, current amperage, shaftrotating speed or any other condition indicators

• Cost-effective Asset Reliability strategy

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Monitoring Modules

Vibration• Tri-axial vibration

RPM• Measure shaft RPM by Hall Effect

Amperage• 3-simultaneous channels for

motor’s 3 phases

Temperature• Thermocouple: range of -210° to 1800° C• Contactless: -50° to 350° C

General Purpose Input• Displacement sensor• Pressure sensor• Lubrication condition sensor

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Benefits• Extend machine life

• Prevent unexpected machine failure / emergency shutdowns

• Prevent catastrophic damage / accidents

• Diagnose machine faults at early stage and predict time to failure

• Reduce unnecessary over-haul and maintenance costs

• Reduce machine outage downtime

• Energy Efficiency

• Reduce vibration-induced noise & nuisance

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IoT System

• V-Sensing VCMonline Series SpiderWeb Wireless tri-axial system

• IoT system for long-term continuous condition monitoring

• Continuous monitoring the mechanicalcondition of the machines with smart onlinealarm system for abnormal findings

• Ideal plant Predictive Maintenance solution

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Vibration Diagnosis

• Coupling misalignment

• Mass imbalance

• Roller element bearing fault

• Sleeve bearing problem

• Mechanical looseness

• Electrical line problem

• Gear problem

• Impeller problem

• Belt and pulley problem

• Structural issues

• Flow problems

And many more…

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FAST FOURIER TRANSFORM

(FFT)

• Our Monitoring System diagnoses machine fault(s) by identifying thevibration frequencies (type of fault) and the corresponding levels (severity)

• With our qualified vibration experts, the recorded FFT spectra will becompared with our pre-set machine fault and bearing database forbaseline alarm setting and diagnosis

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• V-Sensing VCMonline Series offers complete bearing databasecontaining over 30,000 bearings:

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Example: Water-Cooled Centrifugal Chiller (Gear-driven)

Motor

Coupling

High-speed Gearbox Impeller

Cooling Fan

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• Typical faults of gear-driven centrifugal chillers:

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Alarm System

• Alarm level & triggering setting from statistical or baseline data

• Individual alarm triggering by vibration, current, RPM, temperatureor other machine condition indicators

• Provide indication to the plant managementfor quick response prevent furthermachine damage or catastrophic accidents

• Alarm signals in text / code form to be sentto management and engineers via LoRa WAN

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Trending• V-Sensing VCM program will trend the entire machine life cycle

Roller Bearing Fault

Severe Screw Lobe Wear

Stage 2 & 3Random Fault

Site / Online VCMPredictive Maintenance

Stage 1Infant Mortality

T&C

Stage 4Wear Out – Failure

InvestigationBall Bearing Fault

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• Gear Mesh Problem

High Gear Mesh Frequency (GMF) +1x driver / driven RPM sidebands(depends on where the bad gear is)

Regular lubricating oil analysis isrecommended

GMF = No. of teeth x Shaft Speed

Driven Speed = Driver Speed x Driver Teeth / Driven teeth

*Figure from Mobius Institutehttps://www.mobiusinstitute.com

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Early Stage(5 – 10% bearing life remaining)

Mid Stage (Ball defect)(1 – 5% bearing life remaining)

Mid Stage (Outer Ring) Mid Stage (Inner Ring) Late Stage (severe)(Replace bearing ASAP)

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• Bearing Fault – Stage 3(Ball / Roller Damage)

Non-synchronous harmonics at Ball SpinFrequency (BSF) + Fundamental TrainFrequency (FTF)

Impact each time the damaged areacontacts the inner / outer race canbe observed from time waveform signal

Remaining bearing life: 1% - 5%

W a v e f o r m2 7 / 8 / 2 0 1 8 1 1 : 4 6 : 1 9

s e c s0 0 . 0 5 0 . 1 0 . 1 5 0 . 2 0 . 2 5 0 . 3 0 . 3 5 0 . 4 0 . 4 5 0 . 5

mm

/s

- 5 0

- 4 0

- 3 0

- 2 0

- 1 0

0

1 0

2 0

3 0

4 0

5 0O / A l l 1 0 . 5 1 m m / s R M S

T r u e p k - p k 8 1 . 4 5 m m / sC r e s t F a c t o r 3 . 8 7 4

2 7 / 8 / 2 0 1 8 1 1 : 4 6 : 1 9 O / A l l 1 0 . 5 1 m m / s R M S 1 4 8 5 R P M

*Figure from Mobius Institutehttps://www.mobiusinstitute.com

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Specification - Vibration• Wireless tri-axial accelerometer + temperature sensor• Sampling rate: 25,600 Hz• 10 kHz Fmax• Max. 6,400 lines of resolution• Full waveform & spectrum data• Programmable internal RMS trigger

• Battery type: 3.6 V Li – TL-5935• Battery life: 2 – 4 years• Wireless Data transmission: 2.4 GHz BLE 5.0• IP67 – dust & water-proof• Operating temperature: -40°C – 85°C

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Specification - Amperage

• Wireless 3-phase current module• Sensor type: Non-invasive clamp type• Sensor range: 50 / 150 / 500 / 1000 A• 50 / 60 Hz up to 400 Hz• Accuracy: ±0.5 / ±1.5 / ±1 / ±1%

• Battery type: 3.6 V Li – TL-5935• Battery life: 5 – 9 years (4 – 6 collections per day)• Wireless Data transmission: 2.4 GHz BLE 5.0• IP67 – dust & water-proof• Operating temperature: -40°C – 85°C

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• Wireless RPM module• Sensor type: Hall Effect - Omnipolar• Sensor range: 0 – 200,000 RPM• Sensor gap: 1 – 15 mm• Magnet type: Neodymium

• Battery type: 3.6 V Li – TL-5935• Battery life: 5 – 9 years (4 – 6 collections per day)• Wireless Data transmission: 2.4 GHz BLE 5.0• IP67 – dust & water-proof• Operating temperature: -40°C – 85°C

Specification - RPM

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• Wireless temperature module• Thermocouple type: K/J/N/R/S/T/E/B• Sensor range: -210°C - 1800°C• Sensor accuracy: 0.15%• Resolution: 0.25°C• Max. wire length: 25 m

• Battery type: 3.6 V Li – TL-5935• Battery life: 5 – 9 years (4 – 6 collections per day)• Wireless Data transmission: 2.4 GHz BLE 5.0• IP67 – dust & water-proof• Operating temperature: -40°C – 85°C

Specification - Temperature

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• Wireless general purpose input module Shaft displacement Pressure

• Simultaneous 2-channel measurement• Input range: ±3 Volts / ±24 Volts• Amplitude range: 24 bits – 108 dB• Sampling rate: 44.1 kHz

• Battery type: 3.6 V Li – TL-5935• Battery life: 2 – 4 years• Wireless Data transmission: 2.4 GHz BLE 5.0• IP67 – dust & water-proof• Operating temperature: -40°C – 85°C

Lubrication Condition Speed

Specification – General Purpose Input

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Specification (cont’)

Weight: 100 grams

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Setup

• Vibration monitoring at the bearing locations of the machines inthree orthogonal directions (horizontal, vertical & axial):

• Vibration sensors shall be attached to the bearing housing by strongmagnet, adhesive or permanent stud mount

• Current amperage monitoring at the 3 phases of the motor currentinput by clamp meters

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• Example of wireless vibration sensor setup:

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Schematic DiagramMonitoring & Data Transmission Station(IP65 plastic enclosure (Dimensions: 320x240x110mm))

*BLE - Bluetooth Low-Energy 5.0(Connect max. 100 sensors per gateway)

LoRagateway(EMSD’s LoRa

infrastructure)

BLE

Chillers / Compressors

BLE

BLE

220V AC power

Wireless gateway

RS485 to LoRainterface

Data processor

LAN cable

RS485Wifi

routerWifi

LoRaWAN

Water Pumps

Air-Handling Units

BLE

Cooling Tower Fans

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Consultancy Services

• Vibration data analysis by V-Sensing Lab’s Certified VibrationAnalyst* regularly

• Early-stage fault detection and diagnosis

• Review triggering alarm level(s) regularly

* V-Sensing Lab's vibration analysts are qualified inaccordance with ISO 18436-2:2014 "Condition monitoringand diagnostics of machines -- Requirements for training andcertification of personnel -- Part 2: Vibration conditionmonitoring and diagnostics"

V-Sensing Lab

ContactFor more information, please contact our NDT engineers:

Andrew YEUNG Email: andrew@infrared.hkNigel KO Email: nigel@infrared.hk

V-Sensing Lab(A branch of Infrared Engineering & Consultants Limited)

Address: Suite 1603, 16/F, Chinachem Johnston Plaza,178 - 186 Johnston Road, Wanchai, Hong Kong

Tel: +852 2550 2330Fax: +852 2550 1179Website: V-Sensing.comEmail: info@V-Sensing.com