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TIMKEN
Bearing Diagnostics and Bearing Diagnostics and Prognostics Using PIPrognostics Using PI
Reducing Unplanned DowntimeReducing Unplanned Downtime
Rich Browner - Program ManagerRich Browner - Program ManagerReliability SolutionsReliability Solutions
The Timken Company, Torrington OfficesThe Timken Company, Torrington Offices
59 Field Street59 Field StreetTorrington, CT 06790Torrington, CT 06790(860) 626-2699 Phone(860) 626-2699 [email protected][email protected]
TIMKENOSIsoft User Conference 2003San Francisco
Company BackgroundCompany Background
Leading bearing company in the Leading bearing company in the U.S.U.S.
3rd largest bearing company in 3rd largest bearing company in the worldthe world
Torrington Company recently Torrington Company recently acquired from Ingersoll-Randacquired from Ingersoll-Rand
Timken now offers the most Timken now offers the most comprehensive array of bearing comprehensive array of bearing products on the market todayproducts on the market today
TIMKENOSIsoft User Conference 2003San Francisco
New Business OpportunityNew Business Opportunity Help our industrial customers derive more Help our industrial customers derive more
value from their rotating equipmentvalue from their rotating equipment Suite of product-services to help end users Suite of product-services to help end users
select, install, operate and maintain select, install, operate and maintain bearings more effectivelybearings more effectively
Enabled by the new communications Enabled by the new communications infrastructureinfrastructure
Bearing reliability dataBearing reliability datais key to success is key to success
Ensure Bearing Failure Does Not Cause Unplanned Shutdowns
Managed by PI
TIMKENOSIsoft User Conference 2003San Francisco
Identified MarketsIdentified Markets Need identified in the process Need identified in the process
industriesindustries CharacteristicsCharacteristics
Capital intensive processesCapital intensive processes Bearings are a major component of Bearings are a major component of
machine efficiencymachine efficiency Cost of bearing low compared to cost of Cost of bearing low compared to cost of
equipment downtime or failureequipment downtime or failure Improvements in operating efficiency Improvements in operating efficiency
translate into translate into top-line growthtop-line growth Key operating goal is to maximize Key operating goal is to maximize
utilization of rotating equipmentutilization of rotating equipment
TIMKENOSIsoft User Conference 2003San Francisco
Un-Served NeedUn-Served Need
Current situationCurrent situation Knowledge of current equipment health Knowledge of current equipment health
is typically lacking is typically lacking Future situationFuture situation
Accurate predictions of equipment Accurate predictions of equipment failurefailure
Serving that need requires:Serving that need requires: Qualified Qualified real-time diagnosisreal-time diagnosis of bearing of bearing
conditioncondition Accurate Accurate prognosis prognosis of future bearing of future bearing
performanceperformance
TIMKENOSIsoft User Conference 2003San Francisco
Anticipated BenefitsAnticipated Benefits
Prior knowledge of the need for Prior knowledge of the need for equipment maintenance will:equipment maintenance will: Increase uptime and throughputIncrease uptime and throughput Reduce maintenance and repair costsReduce maintenance and repair costs Improve product qualityImprove product quality
Benefits from reduced costs:Benefits from reduced costs:
Reduced CostsReduced Costs
Increased SalesIncreased Sales
Top-Line GrowthTop-Line Growth
TIMKENOSIsoft User Conference 2003San Francisco
Role of PIRole of PI PI manages critical condition dataPI manages critical condition data
Real-time process data (load, temp, Real-time process data (load, temp, pressure, flow)pressure, flow)
Condition data (vibration & acoustic Condition data (vibration & acoustic emissions – 1,000’s of values in arrays)emissions – 1,000’s of values in arrays)
Lubricating oil data (wear debris, Lubricating oil data (wear debris, moisture, condition – 1,000’s of values moisture, condition – 1,000’s of values in arrays)in arrays)
PI provides the connectivity within PI provides the connectivity within the information infrastructurethe information infrastructure
Industrial Evolution enables us to Industrial Evolution enables us to manage equipment health remotelymanage equipment health remotely
TIMKENOSIsoft User Conference 2003San Francisco
Assembling the SolutionAssembling the Solution Tools already exist - need to be assembled Tools already exist - need to be assembled
and applied to and applied to prognosisprognosis Timken working with a team of industry Timken working with a team of industry
experts and products to accomplish this experts and products to accomplish this objective:objective: TechAlerts from Macom – oil debris monitoring TechAlerts from Macom – oil debris monitoring
sensorssensors SS22NAP from RLW – local intelligence platformNAP from RLW – local intelligence platform EXP reliability software from Ivara – manages EXP reliability software from Ivara – manages
total asset healthtotal asset health PI from OSIsoft – manages real-time data and PI from OSIsoft – manages real-time data and
makes it available where neededmakes it available where needed AnyWhere/AnyTime from Industrial Evolution – AnyWhere/AnyTime from Industrial Evolution –
provides remote access for monitoring teamprovides remote access for monitoring team Diagnostic/Prognostic software from Impact Diagnostic/Prognostic software from Impact
Technologies – assesses bearing healthTechnologies – assesses bearing health
TIMKENOSIsoft User Conference 2003San Francisco
Technical SolutionTechnical Solution Local intelligent diagnostics and Local intelligent diagnostics and
prognostics module with wireless accessprognostics module with wireless access Modularized, open architectureModularized, open architecture
Enables system to be configured for specific Enables system to be configured for specific needs of an individual application and userneeds of an individual application and user
Intelligence located near the monitored Intelligence located near the monitored assetasset Large volumes of raw vibration data translated Large volumes of raw vibration data translated
into smaller volume of meaningful informationinto smaller volume of meaningful information Qualified diagnosis of equipment health and Qualified diagnosis of equipment health and
remaining useful life performed continuously in remaining useful life performed continuously in real timereal time
Diagnostic information transferred and Diagnostic information transferred and stored in PI for local and remote stored in PI for local and remote managementmanagement
TIMKENOSIsoft User Conference 2003San Francisco
System ArchitectureSystem Architecture
Reliability Centered Maintenance (RCM)
Software“EXP”
Reliability Centered Maintenance (RCM)
Software“EXP”
Sensors
Data Storage &
Management “PI”
Data Storage &
Management “PI”
Remote Data Access“AnyWhere/AnyTime” – Industrial Evolution
Remote Data Access“AnyWhere/AnyTime” – Industrial Evolution
LocalWireless Network
IP-SecVPN
Tunnel
Field Local Management
Remote Management
Data Acquisition & Analysis
“S2NAP”
Data Acquisition & Analysis
“S2NAP”
Bearing Prognostics“Health Index”
Bearing Prognostics“Health Index”
Oil
Deb
ris &
M
oist
ure
“Tec
hAle
rt”
Vib
ratio
n
Pro
cess
TIMKENOSIsoft User Conference 2003San Francisco
OSIsoft Technology UsedOSIsoft Technology Used Data pushed by SData pushed by S22NAP every minute NAP every minute
in XML formatin XML format Data received and parsed and stored Data received and parsed and stored
into PIinto PI 7,500 data points collected each 7,500 data points collected each
time - includes 9 arrays of 500 pointstime - includes 9 arrays of 500 points MDB and ACE used to deploy the MDB and ACE used to deploy the
Impact Technologies “Health Index” Impact Technologies “Health Index” applicationapplication
ICE and MS-Excel used for viewing ICE and MS-Excel used for viewing the diagnostics and prognosisthe diagnostics and prognosis
TIMKENOSIsoft User Conference 2003San Francisco
System CapabilitiesSystem Capabilities
Vibration sensingVibration sensing Broadband Broadband
analysisanalysis High-frequency High-frequency
narrowband narrowband analysisanalysis
DemodulationDemodulation
Oil analysisOil analysis Wear debrisWear debris Moisture contentMoisture content Oil conditionOil condition
Process dataProcess data
Data acquisitionData acquisition Data analysisData analysis
Advanced Advanced diagnosticsdiagnostics
PrognosticsPrognostics Decision supportDecision support
Wireless data Wireless data transmissiontransmission
Connectivity via PIConnectivity via PI LocallyLocally To enterprise To enterprise
managementmanagement RemotelyRemotely
TIMKENOSIsoft User Conference 2003San Francisco
Prognosis
• Multiple sensor input provides improved diagnostic indicators and reduced false alarms
• Combined feature/model provides more accurate prognostics
Diagnostic/Prognostic ApproachDiagnostic/Prognostic Approach
TIMKENOSIsoft User Conference 2003San Francisco
Enabler for Improved ReliabilityEnabler for Improved Reliability
Service implements advanced Service implements advanced maintenance practices using RCM maintenance practices using RCM methodologymethodology Makes intelligent operational decisions based Makes intelligent operational decisions based
on knowledge provided by this systemon knowledge provided by this system Enables comprehensive reliability services on Enables comprehensive reliability services on
rotating equipment rotating equipment Facilitates reduced maintenance activityFacilitates reduced maintenance activity Allows operators to focus more energy on their Allows operators to focus more energy on their
core businesscore business
Timken will Improve the Reliability of Your Equipment
TIMKENOSIsoft User Conference 2003San Francisco
Remote AccessRemote Access Uses Industrial Evolution web hosting Uses Industrial Evolution web hosting
capabilitycapability People remote from the bearing can view People remote from the bearing can view
results and analyze dataresults and analyze data Plant personnelPlant personnel Timken personnelTimken personnel Macom, RLW & Impact Technologies personnelMacom, RLW & Impact Technologies personnel
This will:This will: Increase the robustness of our diagnostic and Increase the robustness of our diagnostic and
prognostic capabilitiesprognostic capabilities Allow us to monitor customers’ equipment status Allow us to monitor customers’ equipment status
in real time from anywherein real time from anywhere Enable our field service engineers to perform Enable our field service engineers to perform
maintenance at the facility more effectivelymaintenance at the facility more effectively Improve product designs for longer life and Improve product designs for longer life and
increased serviceabilityincreased serviceability
TIMKENOSIsoft User Conference 2003San Francisco
Screen shots
from our demo
system:
www.osiso
ftdemo.c
om
TIMKENOSIsoft User Conference 2003San Francisco
Double-click for an
ad-hoc trend
TIMKENOSIsoft User Conference 2003San Francisco
Enter new time period if required, and “Apply”
TIMKENOSIsoft User Conference 2003San Francisco
Click to download data
to spectrum analysis
spreadsheet
TIMKENOSIsoft User Conference 2003San Francisco
Select a time period and
“Finish”
TIMKENOSIsoft User Conference 2003San Francisco
TIMKENOSIsoft User Conference 2003San Francisco
Vibration and oil debris
distribution data populates spreadsheet
and analysis is performed
automatically
TIMKENOSIsoft User Conference 2003San Francisco
Click to view oil debris analysis
TIMKENOSIsoft User Conference 2003San Francisco
Minimize or scroll down to
see Mass Accumulation
trend
TIMKENOSIsoft User Conference 2003San Francisco
TIMKENOSIsoft User Conference 2003San Francisco
Click to personalize
layout
TIMKENOSIsoft User Conference 2003San Francisco
Drag Web parts to desired
locations
TIMKENOSIsoft User Conference 2003San Francisco
TIMKEN
DemoDemo
www.osisoftdemo.comwww.osisoftdemo.com