Instrumented and Actuated SystemsCondition Monitoring of Rotating Equipment

Mark Bitto / ABB Inc / PSPG / CIBO Technical Focus Group / June 2015

Condition monitoring of rotating equipmentAbout the speaker

© ABB Inc.June 3, 2015 | Slide 2

Speaker name: Mark Bitto

Speaker title: Global Products Marketing ManagerProduct Group Automation ProductsBU Power Generation

Company name: ABB Inc.

Location: Wickliffe, OH, USA

Contact: mark.bitto@us.abb.comwww.abb.com/symphonyplus

© ABB Inc.June 3, 2015 | Slide 3

Condition monitoring of rotating equipment Asset management and optimization

Wealth of plant data used to identify and alert on degrading asset performance before failure occurs

All asset levels: field devices, process / electrical / environmental equipment, control loops, power supplies, communication and network equipment, etc.

Moves maintenance from corrective maintenance program to proactive or predictive maintenance program

Condition monitoring of rotating equipment Why is it important?

Rotating machines are the backbone of nearly all major plant operations

Steam and gas turbines

Motors

Generators

Agitators

Fans, pumps and compressor systems

Modern reliability studies show that nearly 66% of all machine failures occur randomly –with early but often

undetected warning signs

© ABB Inc.June 3, 2015 | Slide 4

Measurement of vibration levels can detect degrading performance -- The greater the vibration, the less the ”smoothness,” and the greater the potential for equipment failure or unplanned shutdown

Condition monitoring of rotating equipment Vibration related machine problems: Causes

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Function: Machine has moving components which are subject to forces due to dynamics of motion: rotation, cyclic motions, impacts

Inadequate design: Machine elements and surfaces are not designed to deal with functional forces, and the resulting non-functional motions are of larger amplitude than desired/designed

Manufacturing processes: Machine surfaces and parts are not made according to spec and/or required tolerances, allowing for either too loose or too tight fits, contributing to rubs, impacts, etc.

Installation: Many opportunities during installation to create poor vibration scenarios: misalignment of train elements (motor/fan or motor/pump), misalignment of bearings and couplings, loose foundations and bolting to foundation, faulty component application

Wear and Abuse: Typically due to poor maintenance practices, not

solving issues, not monitoring for problems

Operational maintenance: Reactive maintenance strategy, run to

failure, inappropriate routine & periodic maintenance, creating long-

term problems with components

Consequences• Catastrophic machine failure• Parts fatigue failure• Loss of efficiency & production quality• Human safety factors: annoyance, injury, death

Condition monitoring of rotating equipment Relation between vibration and bearing life

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% Increase in Bearing Life

% Reduction in Vibration Ball Bearings Other Rolling Element Bearings

5 17 19

10 37 42

15 63 72

20 95 110

25 137 161

30 192 228

40 363 449

50 700 908Source: L. Douglas Berry, Vibration Versus Bearing Life, Reliability, Vol. 2, Issue 4, November 1995

Impact of Vibration Reduction on Bearing Life

(Assuming Dynamic Load is the Major Force Component)

Condition monitoring of rotating equipment Realizing the value of a proactive / predictive maintenance strategy

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An active maintenance strategy with structured work process and modern tools enables early fault detections, reduces costs and avoids expensive breakdowns

© ABB Inc.June 3, 2015 | Slide 8

An active maintenance strategy with structured work process and modern tools enables early fault detections, reduces costs and avoids expensive breakdowns

Condition monitoring of rotating equipment Realizing the value of a proactive / predictive maintenance strategy

Condition monitoring of rotating equipment Major measurement categories

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Major measurement categories: Motion (vibration, eccentricity) Position (thrust, rotor position,

differential expansion, case expansion)

Phase Speed

High

Pressure

Turbine

Low Pressure

TurbineGenerator

Eccentricity

Speed

Event Marker

Case Expansion Differential ExpansionThrust Position

XY VibXY VibXY VibXY Vib XY VibXY Vib

Case Expansion

Process parameters: Load Flow Valve position Temperature Pressure Others…

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Condition monitoring of rotating equipment Prioritizing asset management focus

Critical (5%)

High (25%)

Medium (30%)

Low (40%)

Protection and Condition Monitoring (Wired continuous monitoring)

Asset categorization

Protection and Condition Monitoring (Wired or wireless continuous monitoring)

Condition Monitoring (Wireless continuous or periodic monitoring)

Condition Monitoring (Wireless periodic or no monitoring)

Dangerous failure modes, Potential high cost equipment failure

High value of production loss if failure

Medium value of production cost if failure

Low value of production cost if failure

Rotating machines are the backbone of nearly all major plant operations

© ABB Inc.June 3, 2015 | Slide 11

Condition monitoring of rotating equipment System overview

Vibration Analysis Server

Vibration Analysis Client

DCS HMI workplaces

Process Controllers

Condition Monitoring Modules

Wireless Condition Monitoring Modules

Gateway

System Servers

Displays the waveform data and process variables in variety of plot types

Monitor current condition of the equipment

Compare present and past conditions to assist in predicting potential risks and failures, and preparing for schedule outages

Allow configuration of the vibration modules prior to equipment operation

Condition Monitoring of Rotating Equipment Vibration analysis

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Process variables High-precision waveform data

X – Y plot Time waveform

Bode plot Direct orbit

Polar plot Direct time waveform

Polar + trend plot (Full) spectrum

Filtered orbit plot (Full) cascade

Shaft centerline plot

Plot types allow vibration specialist to easily determine root cause of degrading rotating equipment performance

Condition Monitoring of Rotating Equipment Streamlined proactive remediation work process

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High performance HMIalarm notification

SMS alarm notification+

Call acknowledgement

Rotating equipment –normal state

Rotating equipment –alarm state

Seamless interaction between

HMI and CMMS

Maintenance –vibration specialist

Root cause analysis via vibration analysis packageProactive response

View current CMMS schedules from directly high performance HMI

If not scheduled, create and submit CMMS malfunction report from high performance HMI

Predictive condition alarming SMS alarm notification with remote users Detailed root cause analysis Easy communication with and navigation to

asset specific CMMS activities Quick resolution of maintenance issues before

catastrophic failure occurs

Condition monitoring of rotating equipment Summary

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Improves operation by using proactive rather than reactive maintenance

Reduces annual maintenance costs by minimizing scheduled (but not required) maintenance practices

Continuous on-line performance monitoring eliminates production losses due to unplanned outages

Extends the life of rotating equipment by identifying performance degradation early (before costly replacement or service required)

Minimizes safety events due to catastrophic failures

Integration with DCS increases awareness of performance issues and streamlines the remediation process

© ABB Inc.