Plant Condition Monitoring

Condition Monitoring of Plant Assets (Machinery)

A method to manage machinery assets, so their

operation can be optimized

along with the process

Condition monitoring

Condition monitoring systems is capable of providing the exact information required to the right people at the right time for uninterrupted and trouble free operation of the machinery

Levels of Condition monitoring

Level 1 Visual inspection

Level 2 Sensor-assisted inspection

Level 3 Indicator analysis

Level 4 Computer aided data acquisition system

Level 1 Visual inspection

Seeing

Hearing

Touching

Smelling

Level 2 Sensor-assisted inspection

Data recording with the assistance of portable instruments

Level 3 Indicator analysis

The condition of lubricant, presence wear debris in gear box

oil or engine oil should be

analyzed in a sophisticated test

laboratory

Level 4 Computer aided data

acquisition system

Condition monitoring involves Computer aided data

acquisition system

Condition monitoring

Vibration Analysis

Lubricat (oil) analysis

Alignment

Mass balancing

Ultrasound analysis

Benefits from Condition Monitoring

& Diagnostic System

Optimized plant efficiency, reliability and availability

Monitoring process under normal and critical

conditions

Reduce outage time resulting from operational

errors

Reduced maintenance cost

Machinery Management System

can be broken into five sections

Machinery Measurements

Machinery Protection

Machinery Condition Data Acquisition

Machinery information System

Interface to share the information with anyone on the Plant Network

Organizing the Program

List critical machines to be

included in the program.

Establish the acceptable levels of

machinery vibration.

Determine the normal vibration

characteristics for each machine

(vibration signature base line)

Organizing the Program

Select, identify periodic check points for all machines under this programme

Select the interval for periodic vibration checks

Design a simple data recording & storing system

Organizing the Program

Develop an adequate data

analysis procedure

Train additional personnel to

carry out the program

Machine Category

Critical Machinery

Essential Machinery

General Purpose Machinery

Critical Machinery

The group of rotating equipment which is absolutely

necessary to a major part of the

plant process.

Machines in this category are usually unspared and should

be monitored continuously.

When critical machinery is not operating, that part of

the process is not operating,

the overall plant is not

operating.

Essential Machinery

The group of rotating equipment which is critical to a

part of the plant process.

Machines in this category can be spared or unspared and

should be monitored

continuously.

When essential machinery is not operating, the overall

plant is not operating to full

capacity.

General Purpose Machinery

The group of rotating machinery which is not critical

to any part of the overall plant

process. Many of these

machines have tandem or

spared installations.

Many of these machines are not monitored or are periodically

monitored (monthly or weekly) by a

technician with a portable

monitoring device.

Methodology for machine

malfunction diagnosis

Know the basic mechanical, fluidic, thermal, and electrical (as applicable)

characteristics of the machine (Critical

speeds, Mode shape, Amplification factor)

Know the types of malfunction mechanisms and their corresponding

symptoms that the machine is likely to

incur (unbalance , Flid induced Instability,

Thermal warping, etc.)

Methodology for machine

malfunction diagnosis

Monitor the key parameters that will indicate a change in condition of the machine

(eccentricity, thrust position etc.)

Reduce diagnosis data into interpretable formats and compare the results with

analytical predictions (Half spectrum, Full

spectrum, Orbit & Shaft centerline plots, etc.)

Methodology for machine

malfunction diagnosis

Present data on the machine condition in as solid engineering form as possible

Take prompt action based on the machine diagnosis

German Standard VDI 205

Lubrication analysis

Properties of

Lubricating oil Viscosity

Colour

Specific gravity

Viscosity Index

Acid number

Pour point

Flash point

Aging

Foaming

De-emulsification

The four fundamental laws

of lubrication

Select the Correct lubricant

Keep it Clean

Keep it Dry

Keep it Cool

Lubrication analysis

How is oil cleanliness quantified?

How clean is new oil?

How clean does your oil need to be?

What improvements in machine life can you expect from cleaning up

your oil?

Machinery Management System

A method to manage rotating machinery assets,

so their operation can be

optimized along with the

process

A machinery management system provides data or

information that is

interpreted and applied by

people to correctly operate,

maintain, improve the

operation and assess the

condition of machinery.

Objective Of Machinery

Management System?

To improve profit margins by increasing machine efficiency, reducing or eliminating unscheduled down time and reducing overall operation maintenance cost

Machine Condition Data Acquisition

Machinery measurement

Machinery measurement

Radial vibration

Axial thrust position

Eccentricity

Mode Shape

Differential thermal expansion

Machinery Protection

Protection systems are used to ensure personnel safety,

prevent or minimize

machine damage & limit

environmental impact

South africa

UFFL

Machinery Protection

The machine Protection systems should be able to

monitor more than just overall

vibration amplitude

Machinery Protection

By monitoring more than just overall vibration

amplitude, you can help

increase machine

availability & reduce

machine costs

Machinery Protection

The shutdown signals that may come from the

monitoring system for a

protective action should not

go through the control

system

Machinery Protection

The relays associated with the monitoring system

should provide the shutdown

signals or protective action

directly to the emergency

shutdown system