View
224
Download
1
Category
Preview:
Citation preview
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
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
Recommended