Dynamic Analysis and Vibration Measurement: Ensuring Optimised and Reliable Operations
Reliable and cost-effective plant operation is essential in modern manufacturing and production.
Proper functionality often depends on the mechanical condition of rotating machinery, such as bearings and balance levels.
However, beyond mechanical condition, the design of structures and components plays a crucial role in optimising plant performance. Yet, the drive for efficiency and optimisation often introduces challenges, such as unwanted vibrations in machines, equipment, piping, or structural elements.
The Challenges of Optimisation
Efforts to improve productivity, reduce energy consumption, and optimise designs often lead to lighter and more slender components. This, in turn, can increase dynamic sensitivity, and vibration risks. For example:
- Paper and Cardboard Machines: Higher operating speeds can result in elevated vibration risks.
- Pulp Mills: Record-sized mills face possibility for unexpected dynamic issues during pumping processes.
- Energy Production: High flow rates in energy generation systems can result in flow-induced vibrations and noise emissions.
- High-Speed Components: Optimised rotating machines are prone to issues like torsional vibrations and gyroscopic effects.
While lightweight rotating components reduce energy consumption and align with sustainability goals, these designs are also more susceptible to dynamic challenges; a balance that manufacturers must carefully manage.
The Role of Cost Efficiency and Maintenance
Manufacturing cost efficiency is vital in maintaining market competitiveness. Large-scale industrial projects can benefit significantly from proper optimisation of materials and manufacturing costs. However, when considering operational costs, strategic maintenance and well-planned shutdowns become critical for profitability. By thoughtfully planning over the long term, businesses can meet sustainability goals while maintaining competitive production levels.
The Importance of Dynamic Design Considerations
Structural design that prioritises material cost efficiency can easily meet static load requirements. However, dynamic loads are often oversimplified or overlooked altogether, leading to unforeseen issues after the plant starts operating. This can result in equipment malfunction, production losses, or even structural failures. To avoid such costly outcomes, thorough considerations during the design phase are critical. Key questions to address include:
- Could dynamic loads arise even if they aren't currently specified?
- Are the provided load data accurate, and could combined effects occur?
- Do designers fully understand how the system interacts and operates?
Answering these questions often requires multidisciplinary collaboration and effective communication between teams. For modified equipment, measurements can determine actual load conditions and behaviours, enabling more accurate designs.
Accurate Modelling and Measurements for Reliable Solutions
Finite Element Method (FEM) analysis is a common approach used to model designs and evaluate dynamic behaviour. However, the accuracy of FEM relies on a deep understanding of structural phenomena and behaviours. It's important to remember that simulations are simplifications of real-world conditions, which can result in deviations between calculations and actual system performance. Factors such as modelling scope, manufacturing quality, and assumptions all impact the precision of analysis.
To achieve high-quality outcomes, acceptance testing plays a crucial role. It not only confirms that equipment functions as expected but also delivers invaluable insights for predictive maintenance strategies. Key areas evaluated during acceptance testing include:
- Conformity: Does the machine meet agreed vibration levels and comply with standard requirements?
- Dynamic behaviour: Are natural frequencies and mode shapes accurately identified?
- Mechanical condition: Factors assessed include bearing conditions, unbalances, manufacturing precision, installation success, and more.
Measurement data can uncover issues such as uneven foundations, inadequate attachments, or insufficient structural stiffness. When all measured values fall within agreed limits, test results can serve as a reference point for future bearing condition monitoring, ensuring natural frequency effects are accounted for.
Additionally, dynamic behaviour testing provides a foundation for long-term maintenance planning. It allows ongoing monitoring of structural integrity, aiding in the early detection of fatigue damage or deterioration in critical elements, such as concrete structures.
By prioritising thorough acceptance testing, organisations can enhance operational reliability, extend equipment lifespan, and support a proactive approach to maintenance management.
Why AFRY?
At AFRY, our team of experienced experts specialises in tackling challenges across various industrial sectors. By combining technical expertise with state-of-the-art measurement tools, we ensure accurate analyses and practical design solutions. Whether you're optimising new systems or addressing existing issues, AFRY’s integrated approach serves as a comprehensive resource to overcome challenges and enhance your operations.
Ensuring Reliability Through Smart Design Choices
Optimising materials without sacrificing performance is a fine balance. Focusing solely on cost reductions can lead to vibration or noise issues, introducing risks of equipment malfunction and production losses. By ensuring dynamic loads are accounted for and utilising advanced design techniques like FEM and acceptance testing, businesses can safeguard long-term operational reliability.
