01
Define the machine train and points
The monitoring hierarchy should identify unit, mill, motor, pinion, gearbox, input shaft, output shaft, bearing location and measurement direction.
- Motor drive and non-drive ends
- Pinion radial and axial points
- Gearbox input and output locations
- Speed and process-state context
02
Combine overall values with diagnostic records
Velocity RMS supports condition trend while acceleration waveform and FFT provide frequency evidence around an event.
- Overall velocity trend
- Acceleration and envelope bands where applicable
- Waveform and spectrum record
- Event timestamp and operating state
03
Design alarm logic for process operation
Coal-mill vibration can change with load, startup and transient process conditions. Alarm persistence and operating-state logic reduce nuisance events.
- Warning and danger thresholds
- Persistence and hysteresis
- Machine-running enable logic
- Event de-duplication
04
Plan server and data retention
The system should separate fast diagnostic records from long-term trend storage and aggregated history.
- Local server or approved plant network
- Raw event retention
- Long-term overall trend
- Backup and report export
05
Commission point by point
Each channel must be checked for sensor orientation, cable integrity, engineering units and correct dashboard nomenclature.
- Sensor and cable validation
- Channel-to-machine verification
- Baseline measurement
- Alarm review and user training