Machinery Health Monitoringand Analysis

Machinery Health MonitoringMachinery Health Monitoringand Analysisand Analysis

Machinery MaintenanceMachinery MaintenanceMachinery Maintenance

MotorsMotors PumpsPumps TurbinesTurbinesGearboxesGearboxes

Increases Availability and Performance at Minimized Maintenance Cost ofMechanical Equipment

Increases Availability and Performance at Minimized Maintenance Cost ofMechanical EquipmentMechanical Equipment

Mechanical equipment is the greatest source of downtime in process & utility plantsMechanical equipment is the greatest source of downtime in process & utility plants

Machinery Condition MonitoringMachinery Condition MonitoringMachinery Condition Monitoring

“ Understanding machinery condition ensures that the right maintenance is provided at the right time”

Bath Tub Curve of the FailureBath Tub Bath Tub Curve of the FailureCurve of the Failure

Run in Useful life Wear out

Failu

re R

ate

Operating Time

Decreasing Failure Rate

Constant Failure Rate

Increasing Failure Rate

Vibration AnalysisVibration AnalysisVibration Analysis

"Of all the parameters that can be measured non-intrusively in industry today,

the one containing the most information is the vibration signature."

Art Crawford

Vibration AnalysisVibration AnalysisVibration Analysis

MultipleAnalysisOptions

Fault frequenciesto identify specificnature of fault

MultiplePlotOptions

ReportLink

FastIndexing

Expert System Program Documentation

Diagnose Nature of FaultDiagnose Nature of FaultDiagnose Nature of Fault

Automated Screening with Expert SystemAutomated Screening with Automated Screening with Expert SystemExpert System

MultipleDiagnoses

CalculatesProblemSeverity

CalculatesCertainty

Calculates Overall Severity

DiagnosisAcrossEntireMachineTrain

An alarm/screening report, and a first pass at analyzing machine condition

Software for Machinery Health ManagementSoftware for Software for Machinery Health ManagementMachinery Health Management

Data from diverse technologies resides in one database structure – All personnel view the complete history

for each asset – Technologies supported:

• Vibration – portable and online• Alignment & balancing• Motor Diagnostics• Infrared Thermography• Lubrication analysis & Ultrasonics

Oil Analysis

Laser Alignment

& Balancing

Online Condition Monitoring

Ultrasonics

Portable

Vibration

Motor

MonitoringInfrared

ThermographyOil Analysis

Laser Alignment

& Balancing

Online Condition Monitoring

Ultrasonics

Portable

Vibration

Motor

MonitoringInfrared

Thermography

IntegrationIntegrationIntegrationSeven integrated technologies Complete asset health condition into a single databaseAll diagnosis and findings under one asset in RBMviewWhy not have all of the symptoms of the equipment failureKnow the whole story before making a recommendation

Wear

Contamination Chemistry

ExtremeAlarmAlertHigh NormalNormal

Trivector

WAVEFORM DISPLAY 18-OCT-94 08:37:00 RMS = 4.38 PK(+) = 14.53 PK(-) = 11.78 CRESTF= 3.32

0 50 100 150 200 250 300 350

-15-12

-9-6-3

0369

1215

Time in mSecs

Acc

eler

atio

n in

G-s CF ALARM

CF ALARM

PK ALARM PK ALARM

MA#7 - GEARBOX DRIVE-SUCTION ROLLGBX-DSROLL-G3R G-BOX OUTPUT SHAFT - RADIAL

Label: Severe BPFO defect - need actionPriority: 4

ROUTE SPECTRUM 18-OCT-94 08:37:00 OVRALL= .6516 V-DG PK = .6892 LOAD = 100.0 FPM = 3518. RPM = 381.

0 400 800 1200 1600

0

0.1

0.2

0.3

0.4

0.5

0.6

Frequency in Hz

PK V

eloc

ity in

In/S

ec

Freq: Ordr: Spec:

79.29 12.50 .04412

>FAG 61896 G=BPFO

G G G G G G G G G G

BPFO harmonics show severe race defect

Multi-technology Analysis ToolsMultiMulti--technology Analysis Toolstechnology Analysis ToolsTechnology and expertise… tools for decision making– Vibration Analysis

• FFT, waveform, & phase analysis• Automated diagnostics expertise

– Lubrication Analysis• Trivector wear, chemistry, &

contamination analysis– Electric Motor Monitoring

• Automated rotor & stator diagnostics, using current & flux

– Infrared Thermography• Palette & plot annotation tools• Temp profile & histogram analysis

– Alignment & Balancing• Tolerance plots by the job

Reporting for Machinery Health ManagementReporting for Reporting for Machinery Health ManagementMachinery Health Management

Condition tracking anddocumentationReporting for technician and managementActionable information at facility and machine levelMulti-technology asset information repository

Application Integration and OpennessApplication Integration Application Integration and Opennessand Openness

Integration with CMMS application for automated work order generation. MAXIMO and other cmms apps.MIMOSA open standards allianceODBC open connectivity standardsAsset Portal Consolidates information from Machinery Health Manager, Performance Monitor, Real Time Optimizer, and Intelligent Device Manager. – Combines asset information

from multiple plant locations– collects summary-

level information

Integration Conditional Monitoring (CM) with Computerized Maintenance Management System (CMMS)

Integration Conditional Monitoring (CM) Integration Conditional Monitoring (CM) with Computerized Maintenance with Computerized Maintenance Management System (CMMS)Management System (CMMS)

The role of CM is to implement a maintenance strategy (Predictive, Preventive or Breakdown)

The role of CMMS is to manage the execution of maintenance (Providing tool as management of work, spares in inventory, purchasing, regulatory compliance and documentation)

Integration Conditional Monitoring (CM) with Computerized Maintenance Management System (CMMS)

Integration Conditional Monitoring (CM) Integration Conditional Monitoring (CM) with Computerized Maintenance with Computerized Maintenance Management System (CMMS)Management System (CMMS)

The opportunities for new or enhanced benefits of the integration include:– More effective and automated implementation of maintenance strategy– Improved accuracy of CM analysis– Identification of repetitive failure for root cause analysis– Effective communication of machinery health throughout the enterprise

How can these Different Systems Work Together ?How can these Different Systems How can these Different Systems Work Together ?Work Together ?

The CM has evolved in technical wrapped around the measurement technology. In practice, CM has a well developed vocabulary and data set including these parameters:

Plant Machinery HierarchyMachine PriorityMeasurement LocationsMeasurement DefinitionsMeasurement Interval SeverityAlarm Status or Exception

TrendSpectrumTime WaveformThermographic ImageFrequency ComponentDiagnosisPrognosis

How can these Different Systems Work Together ?How can these Different Systems How can these Different Systems Work Together ?Work Together ?

The CMMS is an information intensive application, historically offering its significant benefits through gathering and distributing information about the maintenance function. CMMS has a well developed vocabulary and data set includes:

Plant Machinery HierarchyWork Requests / OrdersWork PlansWork SchedulesLabor Resources / Cost

Parts Inventories / CostsStorage LocationsPreventive Maintenance ActionsPurchase Requests / OrdersSafety Procedures

How can these Different Systems Work Together ?How can these Different Systems How can these Different Systems Work Together ?Work Together ?

Creating an intelligent Connection– It is necessary to effectively connect the shared data between

these systems as the following new types of information and relationships between the systems

Connection between the Machinery Hierarchies of the CM and CMMSCreation of a new CM result known as AdvisoryCreation of Work Requests based on AdvisoriesA Gateway to Automate Communication between the SystemsTracking of Work Request within the CM SystemDisplay of Equipment Histories and Work Plans within the CM System