Ultrasonic Condition Monitoring of Variable Speed Bearings

John Herbert, Trevor Bell, Wayne Hutchinson

Fonterra, New Zealand

Dr James Neale, Hamish Wolstencroft

Energy Research Group, University of Waikato, Hamilton, New Zealand

Abstract:
Predictive maintenance (PdM) is an attempt to evaluate the condition of equipment by performing periodic or
continuous (online) equipment monitoring. The ultimate goal of PdM is to perform maintenance at a scheduled point
in time when the maintenance activity is most cost-effective, while maintaining the desired equipment performance
threshold. The condition monitoring of rotating bearings is a well know application of structure borne ultrasound,
however this is traditionally been limited primarily to fixed speed applications. With increasing focus on plant
automation and energy efficiency many traditional fixed speed motor driven applications are being fitted with
variable speed drives, resulting in variable machine loads. Traditional instantaneous condition monitoring
techniques, such as structure borne ultrasound, rely on a fixed baseline reference frame to determine any
abnormality for further investigation. Under variable load situations it is important to differentiate between a change
in the load condition and the presence of a condition abnormality.
This paper and corresponding presentation will demonstrate the successful implementation of a structure borne
ultrasound condition monitoring programme for variable speed applications in the New Zealand Dairy Industry.
Initially basic equipment was isolated and tested under laboratory conditions to determine the correct monitoring
methodology, followed by in-plant testing of live production equipment. The critical system parameters required to
successfully monitor variable speed bearings will be discussed, including the characterisation of the required speed
window, application load and recommended alarm levels. The primary benefits of this programme are the rapid
testing of more equipment than would otherwise be possible, thereby increasing the level of plant coverage for the
same maintenance budget spend.
.

1.0 Introduction:
Todays production focus is on increased speed,
accuracy, efficiency and economics. In the past
ultrasound and vibration technologies have been used
independently in the condition monitoring of bearings
in rotating equipment. It is becoming more
widespread to use ultrasonic inspection as a
complementary device to support vibration analyses
for bearing condition monitoring and failure
prediction methods.

This report explores the parameters and reliability of

using Ultrasonic technology to detect faults in
common industrial equipment, while operating under
variable speed applications. As an initial test a series
of laboratory tests were established to evaluate the
effectiveness of the proposed methodology across a
wide range of applications. These techniques were
then applied to real world plant based systems for
further ongoing evaluation and development.

To date however this application has been limited to

fixed speed applications, with ongoing condition
referenced to a known good baseline. In a variable
speed application the fixed baseline is no longer valid,
leaving a degree of uncertainty in what the current
refernce baseline should be.

The aim of the research enclosed in this report is to

demonstrate the accuracy to which Ultrasonic
technology can be used to monitor variable speed
equipment in a real world industrial applications in an
effective manner and at similar cost to traditional
fixed speed applications.

With increasing energy costs and ongoing

modernisation of plant equipment and control
systems an increasing number of traditional fixed
speed equiomewnt are being fitted with variable
speed drives (variable frequency drivers). This
eliminates the ability to use the traditional fixed
speed baseline approach for both VA and ultasound
conditon monitoring programmes.

The primary objective of the ultrasonic based

condition monitoring programme is to identify the
early affects of degraded bearing lubrication and also
the early onset of bearing failure. As with any
condition monitoring PdM programme the success or
failure will be largely determined by developing the
correct test procedure and corresponding acceptance
standards (alarm levels).

2.0 Theory:
The typical Ultrasonic sampling frequency
recommended for bearing monitoring is 30Hz. The
relative loudness of the bearing can give a good
indication of the condition of the bearing if the
baseline value is known. The baseline, if not known,
can be taken as the lowest recorded noise that the
bearing gives off whilst under normal operating
conditions.

power transmission systems were employed.

Ultrasonic sound readings and wave recordings were
taken for all motor bearings and auxiliary bearings.)
The equipment was inspected and the position of the
individual bearings located. The readings were taken
at the position on the device, which had the most
direct sound path to the bearing housing. This
position was marked using a permanent marker for
future reference. In many cases this was the grease
nipple, but in cases where such was absent a position
was marked using a permanent marker to insure
readings were consistently taken from the same point.

If the change in the noise emitted by a bearing is

monitored and tracked over time, basic diagnostics
can be carried out. Traditional fixed speed bearing
condition monitoring programmes have identified
that an 8-10dB increase in operating noise above
baseline is a sign that the bearing needs lubrication.
An increase of 16-20 dB is commonly referred to as
the alarm level associated with the onset of initial
failure of the bearing, and an increase that exceeds
35-40 dB will commonly signal pending/imminent
(catastrophic) failure.

The equipment used was an UE Systems Ultraprobe

10000 with the standard contact module and the
magnetic mount contact module, as illustrated in
Figure 1 below.

Under a variable speed application the baseline dB

level for any given bearing becomes a floating
reference that is directly related to the instantaneous
speed. Under these conditions the instantaneous
alarm levels based on the traditional fixed speed 2
level alarm approach outlined above will also float
accordingly. The variation in the baseline dB with
speed is application specific and also heavily
dependent on the width of the speed window within
which the equipment will operate.

Figure 1 Ultraprobe 10'000 with accessories.

The contact module was used when a grease nipple

was present due to its contact surface being a point,
which could be inserted into the grease nipple
insuring an identical point of contact each time. In
cases of bare motor surfaces or enclosed bearing
housings the magnetic transducer was used to obtain
consistent results.

A range of tests were devised to specifically identify

appropriate acceptance standards and the associated
test procedures for variable speed applications.

3.0 Laboratory Testing:

Each of the four test rigs were started at a fixed speed

and the rpm was recorded. Noise levels of each
bearing were recorded next to their identification
number at a frequency of 30 kHz. The dB reading
was taken after 3-4seconds once the value had
stabilised. The speed of each piece of equipment was
then varied through the respective full operational
envelope, with dB readings taken for each bearing at
regular speed intervals. The equipment was given
adequate time to stabilise at each speed setting prior
to measurements being recorded.

3.1 Impact of Speed on dB Level:

The initial focus was to investigate the relationship

between the noise emitted by a bearing (dB) and the
speed of rotation. It was expected that the bearing
noise would increase with increasing shaft speed;
however the harmonics associated with specific
applications were also expected to have some impact
on this overall relationship.
Measurements were taken on variable speed driven
(VSD) equipment in the large-scale laboratory at the
University of Waikato. The following equipment was
tested;

The speed ranges were not the same for each rig as
motor size, transmission ratios and application
dictated the operational envelope of each system.

Smart Pump
Pulp Screen
Water Flume Pump (vertical Impellor)
Air Heater Fan Motor

3.2 Impact of Test Frequency:

Once all the bearings had been tested at 30 kHz the

test frequency was varied in 1kHz intervals across a
range of 24 to 32kHz, to establish if there were any
benefits or limitations to applying frequency tuning
techniques to each of the various test rigs.

The equipment included a variety of motor sizes,

drive arrangements and power transmission
techniques. The drive arrangements and bearing
placements ranged from cantilever to simply
supported. Both belt driven and coupling driven
2

4.0 Results and Analysis:

Bearing 1 dB vs. Shaft Speed

4.1 Smart Pump

50

dB

The smart pump test rig is shown in Figure 2 below,

with the four bearing locations highlighted. The
corresponding dB readings across the available speed
range for each of the four bearings is shown in Figure
3. Across the majority of the speed range the motor
bearing dB level was surprisingly stable with a
variation of less than 5 dB. The pump bearings in
comparison had a slightly wider band, however if the
low speed settings can be ignored (outside normal
operational envelope) a similar dB band could
potentially be identified.

24kHz

40

25kHz

30

26kHz
27kHz

20

28kHz
10

29kHz
30kHz

0
450

495

526

570

600

660

720

780

Shaft Speed (Rpm)

31kHz
32kHz

Bearing 2 dB vs. Shaft Speed

dB

50

24kHz

40

25kHz

30

26kHz
27kHz

20
28kHz
10

29kHz
30kHz

0
450

495

526

570

600

660

720

780

Shaft SPeed (Rpm)

Figure 2: The Smart Pump test rig shown with Motor bearings (3
and 4) and Auxiliary bearings (1 and 2).

32kHz

Bearing 3 dB vs. Shaft Speed

50

Smart Pump - 30 kHz

dB

50
Decibel Reading (dB)

31kHz

24kHz

40

25kHz

30

26kHz
27kHz

20

40

28kHz

30

10

Motor OB

20

30kHz
450 495

Pump IB
10

29kHz

Motor IB

526 570

600 660

720 780

31kHz

Shaft Speed (Rpm)

Pump OB

332kHz

0
400

500

600

700

800

RPM

Bearing 4 dB vs. Shaft Speed

50

dB

Figure 3: The Smart Pump dB level variation with speed (above),

variation in dB with speed and test frequency for each bearing
(left), and overall variance in dB across the speed band for each
test frequency (bottom left).

24kHz

40

25kHz

30

26kHz
27kHz

20
28kHz

When the variation in dB level for each respective

bearing is considered across the test frequency range
of 24 to 32 kHz the underlying dB to speed
relationship tends to be relatively uniform (with a few
exceptions associated with natural resonances and
competing ultrasonic sources). The overall variance
in db level with test frequency was found to be best
in the 30 to 32 kHz range; however care does need to
be taken to ensure that sharp changes in db are not
caused by a badly matched speed and test frequency,
such as the 31 kHz test on bearing number 3 in the
660 to 780 rpm speed band, as indicated.

10

29kHz
30kHz

0
450

495

526

570

600

660

720

780

Shaft Speed (Rpm)

31kHz
32kHz

Variance vs.Frequency
26

Varience (dB)

24
22
20
18
16
14
12
10
22

24

26

28

Frequency (kHz)

30

32

34

4.2 Pulp Screen

Bearing 1 dB vs. Shaft Speed

The pulp screen test rig is shown in Figure 4 below,

with the four bearing locations highlighted. The
corresponding dB readings across the available speed
range for each of the four bearings is shown in Figure
5. Across the majority of the speed range the motor
bearing dB level was once again surprisingly stable
with a variation of less than 5-6 dB. The pulp screen
bearings in comparison had a much wider band, with
the majority of this spread a result of the lowest speed
setting (600 rpm) and the highest speed setting (2700
rpm). In practice the screen would not be operated at
or near either one of these speeds, and if these two
outliers are removed the variation across the
normal operation band is considerably better with a
total band width of only 8-9 dB.

dB

60

24kHz

50

25kHz

40

26kHz

30

27kHz
28kHz

20

29kHz
10

30kHz

31kHz
594

1194

1487

1782

2390

2672

32kHz

Shaft Speed (Rpm)

33kHz

Bearing 2 dB vs. Shaft Speed

60

24kHz

50
dB

In this type of application a sliding baseline would be

required to ensure adequate detection of each
respective bearing condition alarm level.

25kHz

40

26kHz

30

27kHz

20

28kHz

10

29kHz
30kHz

0
594

1194

1487

1782

2390

2672

31kHz

Shaft Speed (Rpm)

32kHz

1
4

Bearing 3 dB vs. Shaft Speed

3
60

24kHz

dB

50

Figure 4: The Smart Pump test rig shown with Motor bearings (3
and 4) and Auxiliary bearings (1 and 2).

25kHz

40

26kHz

30

27kHz

20

28kHz

10

29kHz
30kHz

0
594

Pulp Screen - 30 kHz

1194

1487

1782

2390

2672

31kHZ

Shaft Speed (Rpm)

32kHz

Decibel Reading (dB)

50
40
30

Bearing 4 dB vs. Shaft Speed

Motor OB

20

Motor IB

60

10

Pump IB

50

Pump OB

40

26kHz

30

27kHz

20

28kHz

10

29kHz

dB

0
400

800

1200 1600 2000 2400 2800

RPM

24kHz
25kHz

30kHz

Figure 5: The Pulp Screen dB level variation with speed (above),

variation in dB with speed and test frequency for each bearing
(left), and overall variance in dB across the speed band for each
test frequency (bottom left).

594

1194

1487

1782

2390

2672

31kHz

Shaft Speed(Rpm)

When the variation in dB level for each respective

bearing is considered across the test frequency range
of 24 to 32 kHz the underlying dB to speed
relationship tends once again to be relatively
consistent. The best performance is still at a test
frequency of around 30 kHz for each bearing tested.

32kHz

dB Varience vs. Test Frequency

Varience (dB)

60
50
40
30
20
10
0
22

24

26

28

30

Frequency (kHz)

32

34

4.3 Water Flume Pump

of 24 to 32 kHz the underlying dB to speed

relationship in this instance is very stable, with all
test frequencies showing a variation of 2 dB or less.
Interestingly the 30 kHz range does still produce one
of the best overall results.

The water flume test rig is shown in Figure 6 below,

with the three bearing locations highlighted. The
corresponding dB readings across the available speed
range for each of the respective bearings is shown in
Figure 7. Across the entire speed range the motor
bearing dB level was very steady ( 2 dB). The
corresponding bearing on the impellor shaft was also
very stable with a variation in dB of less than ( 2 dB)
across the full operational envelope.

Bearing 1 dB vs. Shaft Speed

50

dB

In this type of application a standard fixed speed

bearing base condition monitoring programme would
work quite effectively, with no additional input
variables required.

24kHz

40

25kHz

30

26kHz
27kHz

20
28kHz
10

29kHz
30kHz

0
320 330 360 380 400 420 440 480

31kHz

Shaft Speed (Rpm)

32kHz

Bearing 2 dB vs. Shaft Speed

1
dB

50

24kHz

40

25kHz

30

26kHz
27kHz

20
28kHz
10

29kHz
30kHZ

0
320 330 360 380 400 420 440 480

31kHZ

Shaft Speed (Rpm)

32kHz

Bearing 3 dB vs. Shaft Speed

50

dB

24kHz

40

25kHz

30

26kHz
27kHz

20
28kHz

Figure 6: The Water Flume test rig shown with Motor bearings (3
and 4) and Auxiliary bearings (1 and 2).

10

29kHz
30kHz

0
320 330 360 380 400 420 440 480

31kHz

Shaft Speed (Rpm)

32kHz

50
45
40
35
30
25
20
15
10
5
0

Variance vs. Frequency

Motor OB

2.5

Motor IB

2.0

Varience (dB)

Decibel Reading (dB)

Water Flume - 30 kHz

Pump SB

300 325 350 375 400 425 450 475 500

RPM

1.5
1.0
0.5
0.0

Figure 7: The Water Flume dB level variation with speed (above),

variation in dB with speed and test frequency for each bearing
(left), and overall variance in dB across the speed band for each
test frequency (bottom left).

22

24

26

28

Frequency (kHz)

When the variation in dB level for each respective

bearing is considered across the test frequency range
5

30

32

34

4.4 Fan Motor

Bearing 1 dB vs. Shaft Speed

The fan motor test rig is shown in Figure 8 below,

with the three bearing locations highlighted. The
corresponding dB readings across the available speed
range for each of the respective bearings is shown in
Figure 9. Across the entire speed range the motor
bearing dB level was relatively steady ( 3 dB).

40

24kHz

35

25kHz

dB

30

26kHz

25

27kHz

20

28kHz

15

In this type of application, depending on the level of

criticality of the equipment any variation in fan speed
could be adequately addressed by either relaxing the
alarm levels slightly to say 12 and 24 dB respectively,
or maintain them at the standard fixed speed levels of
8-10 and 16-20 dB, with the understanding that a
false alarm or early warning alarm may be
triggered due to speed fluctuations.

29kHz

10

30kHz

31kHz

0
1075 1116 1143 1170 1212 1252 1281 1307

32kHz

Shaft Speed (Rpm)

33kHz

Bearing 2 dB vs. Shaft Speed

40

24kHz

35

25kHz

dB

30

26kHz

25

27kHz

20

28kHz

15

29kHz

10

30kHz

31kHz

32kHz

1075 1116 1143 1170 1212 1252 1281 1307

Shaft Speed (Rpm)

Figure 8: The Fan Motor test rig shown with Motor bearings (3
and 4) and Auxiliary bearings (1 and 2).

Variance vs. Frequency

Varience (dB)

Fan Motor - 30 kHz

Decibel Reading (dB)

50
40
30
Motor OB

20

Motor IB

10
0
1050

33kHz

14
12
10
8
6
4
2
0
22

24

26

28

30

32

34

Frequency (kHz)
1100

1150

1200

1250

1300

1350

4.4 Laboratory Testing Summary

RPM

The controlled laboratory testing provided several

key insights into the viability of using traditional
fixed speed ultrasonic bearing condition monitoring
techniques on variable speed installations.

Figure 9: The Fan Motor dB level variation with speed (above),

variation in dB with speed and test frequency for each bearing
(left), and overall variance in dB across the speed band for each
test frequency (bottom left).

Firstly the recommended test frequency is the same

as far fixed speed applications (30 kHz), however it is
still very important to ensure that the optimum
frequency is used (tuned) for each individual
applications.

When the variation in dB level for each respective

bearing is considered across the test frequency range
of 24 to 32 kHz the underlying dB to speed
relationship in quite variable, with some clear
indications of interference/resonance issues ate
certain test frequencies. Fortunately there is also
several test frequencies thats sowed a relatively
stable variation in dB level across the speed range of
interest, as shown in the 26-27 and 29-30 kHz bands.

Secondly by establishing the application specific

relationship between speed and dB levels a fixed
baseline may be used in certain applications and
where necessary additional compensation can be
made for variations in instantaneous dB levels as a
function of shaft speeds. The ultimate determining
factor in how detailed/accurate these measures are
can be directly tied to the degree of criticality of the
equipment and the preference for having or avoiding
early or false alarms.
6

5.0 In Plant Implementation:

The above approach was applied to a range of
identical fans configured like the fan and motor
configuration shown in Figure 9. Ultrasonic
measurements were taken over 3 successive periods,
with the dB recordings for each Fan shown in Table 1.
In the first instance there does not seam to be too
large a variation in the dB reading for each bearing in
time, however the comparison of like equipment
shows several clear bearings that are of concern
highlighted in red (level 2 alarm) and orange (level 1
alarm lubrication).

The speed of the fans was not the same on each day
that readings were taken, as illustrated by the
variation in dB level seen for each bearing. The
critical alarm levels can still be readily identified, and
appropriate action planned and implemented.

7.0 Conclusions:
The condition of variable speed bearings can
effectively be monitored using structure borne
ultrasound. The primary prerequisite for any such
programme to be successful is the need to carefully
establish the baseline dB levels for each bearing
across the normal operational speed range for each
piece of equipment. Each variable speed bearing can
then be classified into one of three categories:
(a) Fixed speed bearing behaviour,
additional measures required.

(b) Small variation in dB baseline (<5-8 dB),

an expanded alarm level can be used to
minimise the number of false alarms.

Figure 1: Fan arrangement for Fans 1, 2, 3 & 4

Table 1: In plant readings for 4 identical synchronised VSD fans

Machinery
Bearing
Description
Fan 1
1
Fan 1
2
Fan 1
3
Fan 1
4
Fan 2
1
Fan 2
2
Fan 2
3
Fan 2
4
Fan 3
1
Fan 3
2
Fan 3
3
Fan 3
4
Fan 4
1
Fan 4
2
Fan 4
3
Fan 4
4
* Lubrication applied

(c) Significant variation in dB with speed (>1015 dB), establish a speed dependent baseline
and record speed as part of bearing PdM
route. Modern digital ultrasonic guns have
the capability to add this information as part
of the normal operation.

dB Readings
2/09
2/10
2/11
71
54
38
40
53
45
37
35
67
57*
36
41
72
50
31
37

68
53
40
39
48
40
35
37
62
48
38
37
75
50
31
40

66
52
42
38
47
38
50
40
63
49
38
35
77
51
33
38

The determination of which of the above three

categories any given bearing may best fit can also
then be weighted based on plant specific criticality. If
a piece of plant is deemed critical a higher degree
of monitoring can be implemented to provide the
necessary cover. This increases marginally the work
involved, but can still provide a useful time and cost
effective PdM solution.
As part of the baseline establishment process it is also
very important to ensure that the dB readings are
associated with the bearing and not competing
ultrasound form other sources linked to the process,
i.e. in line turbulence (pumps, fans, etc.).

Table 2 below compares the bearings within each

individual fan arrangement against one another whist
comparing the individual bearings against their
equivalent counterparts.
Table 2: Like for like dB comparison

D4 Exhaust
Fan No.
Fan 1
Fan 2
Fan 3
Fan 4

1
71
53
67
72

Bearing
2
3
54
45
57
50

38
37
36
31

no

4
40
35
41
37

Initial inspection shows that bearing #1 has

considerable dB variance across the four fans. The
baseline for this bearing is taken to be 50dB due to it
being the lowest noise emittance for that bearing type.
Bearing #1 is the outboard shaft bearing closest to
the fan housing, #2 is the fan inboard, with the motor
inboard bearing # 3 and motor outboard #4.
7

Ultrasonic Condition Monitoring of

Variable Speed Bearings

By,
Dr James Neale
University of Waikato

Mr Gary Mohr
UE Systems Inc.

Track 2: Manufacturing Process Reliability

1

Introduction to Ultrasound

Where is Hamilton?

Energy Research Group

Overview
Research into improving Industrial Energy Efficiency

Compressed Air

Steam

Utility Loop Optimisation

Heat Recovery and Heat Integration

Pinch Analysis

Industrial Fluid Flow Optimisation

Renewable Energy Solutions

Distributed Generation

Energy Audit Methodology Development

Energy Efficiency Policy Development

Applications of Ultrasound

Airborne

Structure Borne

Energy Research Group

Overview
Numerical Modelling

Computational Fluid Dynamics Modelling

Proprietary Software Development

Economic Modelling

Capital Project Assessment

Energy Future Scenario Modelling

Experimental Investigation & Analysis

Laboratory Scale

Plant Scale

Capital Project Implementation

System Analysis

System Design

Verification

Presentation Overview
1.

Project Rationale
a.
b.

2.

Project Definition
a.
b.

3.

Site: Fonterra Te Rapa

Applications
Variable Speed Applications
Test Variables

Laboratory Testing
a.
b.

Applications
Results

4.

In-Plant Implementation

5.

Conclusions
a.

Implementation in Your Plant?

KAURI

Fonterra
Overview

MORRINSVILLE
MAUNGATUROTO

WAITOA
TATUA

TE RAPA

Process 14 billion litres of milk annually.

HAUTAPU
TIRAU
TE
AWAMUTU
At peak day 70 million litres / day.
ELTHAM
South Island is currently 27% of the total and
KAPUNI
HAWERA
growing.
Make 2 billion tonnes of Dairy products / year.LONGBURN
PAHIATUA
We have 29 manufacturing sites.
18 in the North Island.
TUAMARINA
TAKAKA
8 in the South Island.
BRIGHTWATER
KARAMEA
We have 4,800 staff.
KAIKOURA
HOKITIKA
We are 22% of NZs total exports.
CHRISTCHURCH

Earning in excess of $15USD Billion.

CLANDEBOYE

STIRLING
EDENDALE

EDGECUMBE
LICHFIELD
REPOROA

Fonterra our Unique

Energy Features
NZs largest combined energy user?
29 main sites, nationwide (Fonterra), 198+
electricity connections, 24 gas sites, 4 coal
mines
Biologically degradable product base,
susceptible to supply interruption (inflexible)
Most electrical motors fitted with Variable Speed
Drives (VSD).

Key Facts Fonterra Te Rapa

Te Rapa is located in the North Island of NZ

Te Rapa in Maori means The Seeking
Size of site: 12 ha
Staff on site: 500
Tankers of milk handled each day: 304
Peak milk capacity: 7.5 million litres/day
Site resources:
Product Technical
Laboratory

Fonterra Te Rapa Site

Fonterra Te Rapa Site

Te Rapa Site History

Milk Powder
Plant
(Driers 1& 2)
Commissioned

1967

Drier 5 &
Co-generation
Plant
Commissioned

Drier 4
Commissioned

1990

Drier 1& 2
Upgraded

1991

1997

Cream Plant
Commissioned

1998

2006

New Packing
Lines
Commissioned

Key Products
Milk Powders:
Skim Milk Powder
Whole Milk Powder

Cream Products:
Butter
Anhydrous Milk Fat
Cream Cheese
High Fat Cream Cheese
Frozen Cream

Project Definition
1. Variable Speed Applications
a. Q: How does speed impact condition monitoring of
bearings?
b. Q: What is our acceptance standard?

2.

Test Variables
a.
b.
c.
d.

Speed
Test Frequency
Alarm levels?
How does the acoustic response vary with speed
for different applications/equipment?

Laboratory Testing
The following equipment was used to test
the effect of varying frequency and speed on
the ultrasound level recorded.
Smart Pump
Pulp Screen
Water Flume
Air Heater Fan

Smart Pump

Smart Pump
Bearing noise was measured in dB
at 4 points:
Motor
1 - Outboard Bearing
2 - Inboard Bearing
Pump
3 - Inboard Bearing
4 - Outboard Bearing

Motor Specifications:
25 kW
1475 rpm max.
4

Speed v dB Results 30kHz

Decibel Reading (dB)

Smart Pump - 30 kHz

50
40

Motor OB

30

Motor IB

20

Pump IB

10

Pump OB

0
400

500

600
RPM

700

800

Pulp Screen

Pulp Screen
4

Bearing noise was measured in dB

at 4 points:
Motor
1 - Outboard Bearing
2 - Inboard Bearing
Pump
3 - Inboard Bearing
4 - Outboard Bearing
Motor Specifications
15 kW
2935 rpm max.

Speed v dB Results 30kHz

Decibel Reading (dB)

Pulp Screen - 30 kHz

50
40

Motor OB

30

Motor IB

20

Pump IB

10

Pump OB

0
400

800

1200 1600 2000 2400 2800

RPM

Water Flume

Water Flume
1

Bearing noise was measured in dB at 3 points:

Motor
Motor Specifications
1 - Outboard Bearing
4 kW
2 - Inboard Bearing
960 rpm max.
Pump
3 - Single Bearing

Speed v dB Results 30kHz

Decibel Reading (dB)

Water Flume - 30 kHz

50
40
30

Motor OB

20

Motor IB

10

Pump SB

0
300 325 350 375 400 425 450 475 500
RPM

Air Heater Fan

Air Heater Fan

Bearing noise was measured in

dB at 2 points:
Motor
1 - Outboard Bearing
2 - Inboard Bearing

Motor Specifications
4 kW
1445 rpm max.

Speed v dB Results 30kHz

Decibel Reading (dB)

Fan Motor - 30 kHz

50
40
30
Motor OB
20
Motor IB
10
0
1050

1100

1150

1200
RPM

1250

1300

1350

Summary - Speed v dB
@ 30 kHz
Variation in speed had little effect on dB level of
motor bearings tested at this frequency (less than 5
dB).
Variation in speed had marginally greater effect on
dB level of the application (driven end) bearings (5
to 25 dB). Very application Specific.
Potential for actual in-plant usage bands to be quite
narrow, resulting in a lower dB band in practice.

Smart Pump Frequency

Variation
Pump OB dB vs. Shaft Speed

Pump IB dB vs. Shaft Speed

24kHz

24kHz

50

50
40

26kHz

30

dB

dB

40

20

26kHz

30
20

28kHz

10

28kHz

10
30kHz

0
450

495

526

570

600

660

720

780

Shaft Speed (Rpm)

30kHz

0
450

495

526

570

600

660

720

780

Shaft SPeed (Rpm)

32kHz

Motor IB dB vs. Shaft Speed

32kHz

Motor OB dB vs. Shaft Speed

24kHz

24kHz

50

50
40

26kHz

30

dB

dB

40

20

28kHz

10

26kHz

30
20

28kHz

10
30kHz

0
450 495 526

570 600

660 720 780

Shaft Speed (Rpm)

30kHz

0
450

332kHz

495

526

570

600

660

Shaft Speed (Rpm)

720

780
32kHz

Pulp Screen Frequency

Variation
Screen OB dB vs. Shaft Speed

Screen IB dB vs. Shaft Speed

60
50
40

24kHz

26kHz
28kHz

30
20
10
0

dB

dB

24kHz

30kHz

594

1194

1487

1782

2390

2672

Shaft Speed (Rpm)

32kHz

60
50
40

26kHz

30
20
10
0

28kHz
30kHz
594

1194

1487

1782

2390

2672
32kHz

Shaft Speed (Rpm)

33kHz

Motor OB dB vs. Shaft Speed

Motor IB dB vs. Shaft Speed

24kHz

26kHz
dB

dB

24kHz
60
50
40
30
20
10
0

28kHz
30kHz
594

1194

1487

1782

2390

Shaft Speed(Rpm)

60
50
40
30
20
10
0

26kHz
28kHz
30kHz
594

2672
32kHz

1194

1487

1782

2390

Shaft Speed (Rpm)

2672
32kHz

Water Flume Frequency

Variation
Motor OB dB vs. Shaft Speed

Motor IB dB vs. Shaft Speed

24kHz

24kHz

50

50
40

26kHz
dB

30
20

28kHz

10

26kHz

30
20

28kHz

10
30kHz

0
320 330 360 380 400 420 440 480

30kHZ

0
320 330 360 380 400 420 440 480

32kHz

Shaft Speed (Rpm)

Shaft Speed (Rpm)

Prop dB vs. Shaft Speed

24kHz
50
40
dB

dB

40

26kHz

30
20

28kHz

10
30kHz

0
320 330 360 380 400 420 440 480
Shaft Speed (Rpm)

32kHz

32kHz

Air Heater Frequency

Variation
Motor IB dB vs. Shaft Speed

Motor OB dB vs. Shaft Speed

24kHz

24kHz

40

40
26kHz

26kHz
30

20

28kHz

10
0

20

28kHz

30kHz

10

30kHz

32kHz

1075 1116 1143 1170 1212 1252 1281 1307

Shaft Speed (Rpm)

dB

dB

30

33kHz

32kHz
1075 1116 1143 1170 1212 1252 1281 1307
Shaft Speed (Rpm)

33kHz

Test Frequency Variation

26
24
22
20
18
16
14
12
10
22

24

26

28

30

32

34

Pulp Screen

Frequency (kHz)

Smart Pump

dB Varience vs. Test Frequency

Varience (dB)

Varience (dB)

Variance vs.Frequency

60
40
20
0
22

24

26

28

30

Frequency (kHz)

32

34

Test Frequency Variation

2.5
2.0
1.5
1.0
0.5
0.0
22

24

26

28

30

32

Fan Motor

34

Frequency (kHz)

Variance vs. Frequency

Water Flume
Varience (dB)

Varience (dB)

Variance vs. Frequency

15
10
5
0
22

24

26

28

Frequency (kHz)

30

32

34

Summary - Varying Test

Frequency
Ultrasound level tends higher at lower test
frequency for most speed ranges.
dB level relatively stable with varying motor
speed at all frequencies on motor bearings.
dB level increased on some pump/prop bearings
as speed increased, for all frequencies.

In-Plant Implementation
Fonterra Te Rapa
Condition Monitoring Implemented across a range of critical
variable speed equipment

Water Pumps
Main Inlet & Exhaust Fans to Drier
MVR Fans: Drier Evaporator
Chilled Water Compressors (Ammonia)
Plate Freezer Compressors
VSD Air Compressor

Will be carried out over an extended period to allow long term

trending of results.

In-Plant Implementation
Measurements
dB level
motor speed (using displayed speed or a hand held strobe)
Sound Files

Ultimate Objectives
Traffic Light Assessment
Green good
Red Bad
Amber recheck etc
Avoid Measuring Speed
Keep life simple
Sound File Primary Measure of Bad bearing
Capture Lubrication Fault in timely manner

Implementation
in Your Plant
Establish baselines
What are the speed limits?
High
Low

How does the dB Vary?

Motor
Driven End (Application)

What is your acceptance Standard?

Degrees of criticality
False alarms?
Modified Alarm Levels
Lower level => dB driven
Upper level => Sound File driven

Thank you