understanding and applying different levels of machinery ......automation | valves | measurement |...
TRANSCRIPT
-
Automation | Valves | Measurement | Process Control
Understanding and Applying Different Levels of
Machinery Condition MonitoringPresenter: Carl Sheehan P.Eng.
September 15, 2020
-
Automation | Valves | Measurement | Process Control
Agenda:
• What is Condition Monitoring?
• Technologies for Condition Monitoring
• Reliability Strategies
-
Automation | Valves | Measurement | Process Control
What is Condition Monitoring?
-
Automation | Valves | Measurement | Process Control
Condition Monitoring Enables Moving from Reaction to Prediction
Reaction
Equ
ipm
en
t H
eal
th
0%
100%
Time
advanced warning gives plant time to
respond
Downtime
Prediction & Performance
Re
pair Eq
uip
me
nt
Pla
n M
ain
ten
ance
Ord
er
Par
ts
Ass
ign
Pe
rso
nal
Sch
ed
ule
Se
rvic
e c
on
trac
tor
Reduced
Identify Failure Precursors – Leading Indicators
-
Automation | Valves | Measurement | Process Control
An example.
-
Automation | Valves | Measurement | Process Control
Performance and Reliability are Key
Safety
3X fewer
Recordables and process
incidents
Process
Incidents
4th 1stQuartiles
Recordables
Production
20% lower operating costs
Utilization
4th 1stQuartiles
Operating Costs
10% higher Utilization Rate
4% higher availability
Half the maintenance
costs
Reliability
Availability
Maintenance
4th 1stQuartiles
Emissions
Energy Use
CO2 Emissions
4th 1stQuartiles
30% lower emissions
30% less energy use
Approximately
ONE TRILLION
DOLLARSin company value is
lost every year to
operating performance
suboptimal
-
Automation | Valves | Measurement | Process Control
Condition Monitoring
Technologies
-
Automation | Valves | Measurement | Process Control
Example – AC Induction Motors
Cooling
Fan
Enclosure
Stator
Terminal
Box
Mounting Feet
Bearing
& Seals
Rotor
Shaft
-
Automation | Valves | Measurement | Process Control
How does an Electric Motor Fail?
Bearings
40%
Stator Faults
38%
Rotor Faults
10%
Other
12%Mechanical Faults Electrical Faults
-
Automation | Valves | Measurement | Process Control
Electric Motor – Condition Indicators
TemperatureVibration Lubrication
-
Automation | Valves | Measurement | Process Control
Electric Motor – Vibration Considerations
Vibration
Why Vibration Monitoring?
Common Vibration Causes
How do I check?
-
Automation | Valves | Measurement | Process Control
What is Vibration
• Vibration is the motion of a body about a reference point caused by an
undesirable mechanical force.
• Causes include:
ImbalanceMisalignment
LoosenessBearing Wear
-
Automation | Valves | Measurement | Process Control
Vibration: Imbalance
0
+
-
AMPLITUDE
360degrees
Heavy Spot
1 revolution
Time
1750 rpm
FL
OW
-
Automation | Valves | Measurement | Process Control
Vibration: Misalignment
BEFORE
AFTER
GRRR!
hmmm!
SHAFT
BE
AR
ING
MOTOR
Offset
Angular
Both
-
Automation | Valves | Measurement | Process Control
Vibration: Soft Foot
-
Automation | Valves | Measurement | Process Control
Vibration Measurement: Accelerometers
Time (s)
Acc
el. (
G’s
)
ROTOR
Horizontal
Vertical
-
Automation | Valves | Measurement | Process Control
Time0
+
-
AMPLITUDE
Time0
+
-
AMPLITUDE
Vibration Basics from Mechanical Faults
Time0
+
-
AMPLITUDE
Balance
1 x RPM
Blade Pass
4 x RPM
Gear Mesh
12 x RPM
Component Configuration and Cycles per revolution
-
Automation | Valves | Measurement | Process Control
Time0
+
-
AMPLITUDE
Time0
+
-
AMPLITUDE
Vibration
Time0
+
-
AMPLITUDE
FL
OW
FLOW
FL
OW
Balance
1 x RPM
Misalignment
2 x RPM
Vane Pass
11 x RPM
-
Automation | Valves | Measurement | Process Control
The combined Time Waveformsdo not look like this
-
Automation | Valves | Measurement | Process Control
They look like this
In reality these waveforms are more complex
All the different frequencies are mixed
together in the waveform
Typical Waveform
-
Vibration: Time-Frequency Conversion
1X
900 rpm
15Hz
2X 9900 cpm
165Hz
COMPLEX FIELD TIME DATA
THE COMPLEX TIME DATA ISBROKEN INTO ITS COMPONENTS
IN A PROCESS CALLED
FFT
FAST FOURIER TRANSFORM
THE COMPONETS ARE GRAPHED AS
FREQUENCY VERSES AMPLITUDE
FREQUENCY DOMAIN
FREQUENCY SPECTRUM
SPECTRUM
FFT
-
Automation | Valves | Measurement | Process Control
Vibration: Frequency Alarming
Trend of
Balance
Trend of
Bearings
Alarm
Am
pli
tud
e
Balance AlignmentBearing Bearing Gears Bearing
1x 2x 50x
5mm/sec
1mm/secTime
(Days)
Time
(Days)
-
Automation | Valves | Measurement | Process Control
Electric Motor – Temperature Considerations
Temperature
Why Temperature Monitoring?
Common High Temperature Causes
How do I check?
-
Automation | Valves | Measurement | Process Control
Condition Monitoring Strategies
-
Automation | Valves | Measurement | Process Control
On Demand
Planned
Predictive
Prescriptive Analytics
Condition Monitoring Strategies
-
Automation | Valves | Measurement | Process Control
On Demand
• Periodic high resolution monitoring
• Monitor assets and faults on a monthly
• Manual Collection, Analysis and
Reporting
FL
OW
FL
OW
MOTOR
7X 8Y 5X 6Y
9
TACH
FIX
ED
BE
AR
ING
=
TH
RU
ST
BE
AR
ING
3X 4Y 1X 2Y
1011
-
Automation | Valves | Measurement | Process Control
On Demand
• Periodic high resolution monitoring
• Monitor assets and faults on a monthly
• Manual Collection, Analysis and
Reporting
FL
OW
FL
OW
MOTOR
MECHANICAL FAULTS
• ELECTRIC MOTOR
1. BALANCE
2. ALIGNMENT
3. LOOSENESS
4. BEARING FAULTS
5. MOTOR FAULTS
6. COUPLING FAULTS (PeakVue)
7X 8Y 5X 6Y
9
TACH
FIX
ED
BE
AR
ING
=
TH
RU
ST
BE
AR
ING
3X 4Y 1X 2Y
1011
-
Automation | Valves | Measurement | Process Control
On Demand
• Periodic high resolution monitoring
• Monitor assets and faults on a monthly
• Manual Collection, Analysis and
Reporting
FL
OW
FL
OW
MOTOR
MECHANICAL FAULTS
• ELECTRIC MOTOR
1. BALANCE
2. ALIGNMENT
3. LOOSENESS
4. BEARING FAULTS
5. MOTOR FAULTS
6. COUPLING FAULTS (PeakVue)
7X 8Y 5X 6Y
9
TACH
FIX
ED
BE
AR
ING
=
TH
RU
ST
BE
AR
ING
3X 4Y 1X 2Y
1011
MECHANICAL FAULTS
• ELECTRIC MOTOR
1.BALANCE
2.ALIGNMENT
3.LOOSENESS
4.BEARING FAULTS
5.MOTOR FAULTS
6.COUPLING FAULTS
• PUMP ROTOR
1.BALANCE
2.ALIGNMENT
3.LOOSENESS
4.BEARING FAULTS
-
Automation | Valves | Measurement | Process Control
• Frequent high-resolution Vibration and
Temperature Monitoring
• Permanently-installed monitoring equipment
• Monitor assets and faults on an hourly basis
• Wired or Wireless Collection
Planned
-
Automation | Valves | Measurement | Process Control
• Frequent high-resolution Vibration and
Temperature Monitoring
• Permanently-installed monitoring equipment
• Monitor assets and faults on an hourly basis
• Wired or Wireless Collection
Planned
-
Automation | Valves | Measurement | Process Control
• Frequent high-resolution Vibration and
Temperature Monitoring
• Permanently-installed monitoring equipment
• Monitor assets and faults on an hourly basis
• Wired or Wireless Collection
PlannedMECHANICAL FAULTS
• ELECTRIC MOTOR
1.BALANCE
2.ALIGNMENT
3.LOOSENESS
4.BEARING FAULTS
5.MOTOR FAULTS
6.COUPLING FAULTS
• PUMP ROTOR
1.BALANCE
2.ALIGNMENT
3.LOOSENESS
4.BEARING FAULTS
-
Automation | Valves | Measurement | Process Control
• Continuous high-resolution Vibration and
Temperature Monitoring
• Monitor assets and faults on a second-by-second
basis while incorporating site process data
• Health Scores from the Edge Device provide easy
to understand fault analysis
2
1
3
46
5
TACH
Predictive
-
Automation | Valves | Measurement | Process Control
Edge Analytics Prediction Logic – Examples of Known Failure Modes
Balance
• Running speed amplitude
• 2 times running speed amplitude
• 3 times running speed amplitude
• Running speed amplitude > Balance Level
Other 1X phenomena
1.Resonance
2.Intermittent based on Defects
▪ Rub/Clearance/Runout issues
▪ Mechanical – missing gear tooth
▪ Shaft Crack
Alignment
• Running speed amplitude
• 2 times running speed amplitude relationship to running speed amplitude
Looseness
• Running speed harmonic amplitudes
• Synchronous and non-synchronous energy
VIBRATION SPECTRUM
1X
RUNNING
SPEED
2X 3
X
-
Automation | Valves | Measurement | Process Control
• Continuous high-resolution Vibration and
Temperature Monitoring
• Monitor assets and faults on a second-by-second
basis while incorporating site process data
• Health Scores from the Edge Device provide easy
to understand fault analysis
2
1
3
46
5
TACH
Predictive
-
Automation | Valves | Measurement | Process Control
2
1
3
46
5
TACH
Predictive
MECHANICAL FAULTS
• ELECTRIC MOTOR
1.BALANCE
2.ALIGNMENT
3.LOOSENESS
4.BEARING FAULTS
5.MOTOR FAULTS
6.COUPLING FAULTS
• PUMP ROTOR
1.BALANCE
2.ALIGNMENT
3.LOOSENESS
4.BEARING FAULTS
-
Automation | Valves | Measurement | Process Control
Instrument and Valve Health
Rotating Equipment Health
Machinery Protection and Prediction
DCS
Process Data
Persona based content delivery
Data Analytics Platform
Prescriptive Analytics
-
Automation | Valves | Measurement | Process Control
Analytical Techniques
DATA-DRIVEN
Statistical models
based on data using
regression techniques
(linear, logistic,
polynomial, etc.)
First principles
based on physical and
thermodynamic laws
governing how things work
PRINCIPLES-DRIVEN
EXAMPLE: ESTIMATING PUMP
REMAINING USEFUL LIFE (RUL)
EXAMPLE: PUMP FAILURE EXAMPLE: ASSET AVAILABILITY
PATTERN RECOGNITION
EXAMPLE: PUMP EFFICIENCY
Rules-based
on observation and
domain expertise,
including Failure Mode
Effect Analysis (FMEA)
Pump
Not Available
Pump
Available
40
Advanced analytics
leveraging …
Artificial Intelligence (AI)
and…
Machine Learning (ML)
for pattern recognition
-
Automation | Valves | Measurement | Process Control
Example – Root Cause Analysis
SymptomLow Compressor
Performance
Root CauseExpander Vibration
-
Automation | Valves | Measurement | Process Control
Collect condition
data
Centralized
software
application
Manual analysis /
Expert tools
Manual reporting /
integration to
other systems
C
U
R
R
E
N
T
Collect vibration
and process data,
Apply embedded
analytics
Reports / Alerts /
Messages
delivered to user
Advanced
analytical tools
N
E
W
Remote
Monitoring
-
Automation | Valves | Measurement | Process Control
Results and Benefits
-
Automation | Valves | Measurement | Process Control
Propane Export Facility
• In the first 8 months of operation, over 200 potential risks have been identified
and avoided via this program.
• Included within these risks have been potential failures of the most critical
control valves on site, as well as multiple compressor gearbox and LPG feed
pump faults. All detected with PeakVue, trended and highlighted with the onsite
continuous and periodic vibration monitoring program.
Predictive
-
Automation | Valves | Measurement | Process Control
Pulp & Paper Mill
Year Number of
Unpredicted Failures
2006 52
↓ ↓
2012 0
2013 3
2014 5
2015 4
2016 4
2017 3
2018 4
2019 1
Predictive
-
Automation | Valves | Measurement | Process Control
Summary:
• Condition monitoring enables predictive maintenance
• Many fault-prediction technologies available
• Technologies applied in different programs
• Quantifiable business results
-
Automation | Valves | Measurement | Process Control
Understanding and Applying Different Levels of
Machinery Condition Monitoring
Presenter: Carl Sheehan P. Eng.
September 15, 2020
Questions?