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Optimizing ConditionMonitoring

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Agenda

Asset Management & CM Solutions

Condition Monitoring Technologies

Condition Monitoring Products &Services

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Asset Management

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The Concept

What is an Asset?

Assets of an organization

Competitive advantage &Profitability

Managing your asset

ROI, Payback, NPV, IRR

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ac nery - pr maryasset

Managing your machinery

ROI from your machinery

When does it increase? Maintenance & control

Better Asset Management

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a n enance as a procentre

Maintenance is a cost centre

But can we increase ROI from

machinery? Maintenance a potential PROFIT

CENTRE

But how do we achieve that?

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Life Cycle Profit (LCP)

Time

Indirect maintenance costs

Loss of contribution

Capital costs etc.

Rs

Direct maintenance cos ts

Life Cycle Profit, LCP

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Loss of Contribution

LCP

Direct maintenance costs

Indirect maintenance costs

Loss of contribution

Availability

Performance efficiency (prod.speed, ton/hour)

Quality rate

Overall Equipment Efficiency (OEE)

Goal OEE = A P Q > 85 % WCM

Company XYZ:

A = 95%

P = 95%

Q = 95%

OEE = 95% x 95% x 95%

= 85%

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Direct maintenance costs

Loss of contribution

LCP

Equipment (tools, instruments, etc.)

Wages Spare parts

Contracted services

Overhead costs

Indirect maintenance costs

Direct maintenance costs

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Reduces MaintenanceExpenses

Spares and Consumables

Repair

Manpower Rework/Rejection

Capital & Insurance

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Summary

Better Asset Management Higher ROI Higher Returns from Machinery Asset Increase LCP To Increase LCP

Increase Contribution

Decrease Direct & Indirect Maintenance Exp To increase Contribution and decrease Expenses

Condition Monitoring and Predictive Maintenance (PdM) Corrective Maintenance

SPM provides solutions to achieve that

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Solution Areas

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on on on or ngSolutions

Oil Analysis

Shock Pulse Analysis

Temperature Monitoring

Ultrasound Monitoring

Vibration Analysis

Wear Particle Analysis 00.5

1

1.5

2

2.5

3

0 50 100 150 200 250

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Corrective MaintenanceSolutions

Dynamic Balancing

Machine Alignment using Lasertechnology

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Diagnostic Services

Ferrography Analysis

Shock Pulse Analysis

Vibration Analysis

In-situ DynamicBalancing

Machine Laser

Alignment

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Products

Hardware Instruments Portable

Remote

Surveillance Online Diagnostic Lab

Software

Data Analysis, Trendingand Reporting Training

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Mis-

alignment

Looseness. Worn

coupling

Gear

damage

Bearing

damage

Out of

balance

(Elect&Mech)

Typical Machine Problems

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Bearing life unknown

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Shock Pulse

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Shock Pulse Method

oc u ses rom

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oc u ses romBearings

Bearing & Lubrication

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Bearing & LubricationCondition

Good Bearing, Sufficient Lubrication

Good Bearing, Insufficient Lubrication

Damaged Bearing

ear ng e an oc

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ear ng e an ocPulses

Earliest detection of

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Earliest detection ofBearing damage

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Vibration Monitoring

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Trending Overall Vibration

Vibration severity

+ 4 steps

+ 3 steps

+ 2 steps

+ 1 step

Normal

Inspection,

minor repairs

Plan major

overhaul

(Shutdown)

Effect repairs

Routine

maintenance

(lubrication, etc.)

Vibrationmeasurement

Maintenanceactivities

Breakdown

Report dangerous increase

Report large increase

Report change

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Vibration Analysis

ec an ca au

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ec an ca auFrequencies

Time waveform &

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Time waveform &Frequency spectrum

0

0. 5

1

1. 5

2

2. 5

3

0 50 100 150 200 250

requency pec rum

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requency pec rumAnalysis

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Evaluated Vibration AnalysisMethodEVAM

ymp om parame er

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ymp om parame ermatch

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Identified & Magnitude

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Identified & Magnitude

Calculated

Measured RPM

Spectrum line patternfor gear mesh

Value and match

Input no. ofgear teeth

arame er r er a ase

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arame er r er a aseline)

COND No.

35 - 60 redabove 5 std

21 - 34 yellow3 - 5 std

0 - 20 greenup to 3 std

mm/s

time

Statistical calculation.

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Evaluated Symptom

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60

50

40

30

20

10

0

Evaluated SymptomCondition - Unbalance

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Machine faults identified

Machines Motors

Generators

Pumps Compressors

Fans &Blowers

Gear Box Turbines

Faults Unbalance Misalignment Bearing damage Improper Lubrication Gear problems Belt problems Looseness Electrical

Rotor Unbalance Rotor Eccentricity Rotor Bar defects

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FerrographyWear Particle Analysis

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Condition Monitoringby Oil Analysis

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Two Different Objectives

Monitoring Condition of Oil Lubricant analysis

Physio-Chemical properties

Moisture, TAN, TBN

Monitoring Condition of Equipment Wear Debris analysis

Mechanical components

Bearings, Gears

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Wear Debris Analysis

Particle Counting Spectroscopy

Ferrography Wear Particle Analysis

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Ferrography

Detects wear particles even > 250 insize Provides early indication of abnormal wear

Details of machine condition: Cause

Severity and Component of wear

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Fundamental Concept

Four criteria are considered to evaluate condition:

SIZE : Severity of wear

SHAPE : Wear mechanism / Cause of wear

COMPOSITION : Wearing component

CONCENTRATION : Severity of wear

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Size

Cutting Wear Particles(500X)

150 microns sizeparticle

CRITICAL

50 microns sizeparticle

MARGINAL

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Shape

Sliding Wear Spheres

Desc: Flat elongatedplatelets withstriations

Cause: Excessive load/speedon sliding

Desc: Small spheres

Cause: Rolling contactfailure in

Bearings

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Composition

Bearing Wear

Copper Alloy Low Alloy Steel Lead/Tin Babitt

reddish-yellow colour blue temper colour multi-coloured

on heat treatment on heat treatment

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Analysis Procedure

Sampling and Equipment data

Stage I Quantitative measurement stage

Identify abnormal wear by trending the concentration of wear particles

Quantitative measuring instrument DR Direct Reading Ferrograph

Stage II Analytical stage

Identify the source (component), cause and severity of wear

The FM Ferrograph separates the wear particles by size The Ferroscope is used to evaluate the separated wear particles

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Lab

DR

Softwar

e

Ferroscope

FM

rec ea ng

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rec ea ngFerrograph

Quantitative measuringinstrument

Detects Small (DS) &

Large particles (DL) Measures WPC = DL +

DS

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Ferrogram principle

Distance in mmDistance in mm

EXIT ENDEXIT END

Non-WettingNon-Wetting

BarrierBarrier

0.3x60mm0.3x60mm

Glass SubstrateGlass Substrate< 0.5 Ferrous< 0.5 Ferrous

ParticlesParticles

Non-FerrousNon-Ferrous

DebrisDebris

< 5 > 5 < 5 > 5

Ferrous ParticlesFerrous Particles

S MagnetS Magnet

PolePole

N MagnetN Magnet

PolePole

Flux Lines w/DebrisFlux Lines w/Debris

Non-MagneticNon-Magnetic

Barrier,Barrier,

2.5mm2.5mm

ENTRY POINTENTRY POINT

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Ferroscope

Identify particles

100X, 500X, 1000X

Multiple light sources

Bi-chromatic

Polarized

Video Camera for

capturing image

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Particle Classification

Ferrous: Low Alloy Medium Alloy High Alloy

Non-Ferrous: Copper Alloy

Aluminium Alloy Babbitt (Lead/Tin)

Contaminants: Dust & Dirt

Filter material

External debris

Black Oxides

AluminiumAlloy

Fibers

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Severity Rating of Particles

Subjective: Low concentration, Small size: 0-4

Medium conc., Medium size:

5-7 High conc., Large size:

8-10

vera a ng o

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vera a ng oEquipment

Criteria: Equipment WPC Severity rating of individual particles

Rating: NORMAL

MARGINAL CRITICAL

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Benefits

Provides early warning

Identifies lubricant contamination

Identifies specific failing components

Helps monitor component deterioration

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Condition Monitoring &

Corrective MaintenanceProducts & Services

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Products

Hardware Instruments Portable

Remote

Surveillance

Online Diagnostic Lab

Software

Data Analysis, Trendingand Reporting Training

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Portable Products

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Basic Condition

AutomaticLubrication

Non-contact IR Temperature

MotorChecker

Vibration Velocity RMSmm/s

Vibration Velocity,Displacement, Acceleration.

Crest & RPM

EMC-22 VIB-10 VIB-15

ElectroLube Raytek

Basic Condition & Correction

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BalanSure AT-30

Light & Portable Phase measurement

Dynamic Balancing

Vibrationmeasurement

Speed measurement

Frontline Condition

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Shock Pulse Analyzer A2011

Shock Pulse: Bearing condition

Lubrication condition

Vibration Velocity RPM

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Correction

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Leonova

Shock Pulse: Bearing & Lub Vibration Velocity Vibration FFT Analysis EVAM Shock Pulse Spectrum Temperature RPM Long Time Recording Auto Measuring Point Id 2 plane Balancing

Laser Alignment

eonova oc u se

http://../SPM/MikaelLindfors/SPM%20India/Supporting%20documents/Leonovabyspm/main.exehttp://../SPM/MikaelLindfors/SPM%20India/Supporting%20documents/Leonovabyspm/main.exe

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Spectrum

l i

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Leonova Balancing

Single Plane Dual Plane

li

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Leonova Laser Alignment

Line Laser Horizontal

Vertical

Soft foot Thermal growth

Advanced Trouble Shooting

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DCX

4 channel Vibration Analyzer Tri-axial data collection All-in-One: GB memory Entire Data Base: no routes Expert Analysis: On site report Phase measurement Multi-plane Balancing Run-up & Coast down Orbit, Bode plots

Current Analysis

Machine Laser Alignment

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Fixturlaser Shaft, Roll, Geo

Shaft Alignment Geometric

Alignment

Roll Alignment Turbine Alignment

Bore Alignment

Ultrasound Monitoring

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Accutrack VPX

Air Leaks Valves

Steam Traps

R t M it i

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Remote Monitoring

Measure: Shock Pulse Overall Vibration

System consists of: PermanentTransducers

Connector & Cable

Terminal Box Portable Instrument Measurement

O li S ill

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Online Surveillance

Measure: Temperature

Shock Pulse

Overall Vibration

4-20mA, BufferOutput

Alarm, Trip

Vibration TransmitterVT1C & VT2C

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VT1C & VT2C

Measures OverallVibration Severity 1 ch, 2 ch

4-20 mA output Buffer output

Vibration SwitchVS1C

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VS1C

Measures OverallVibration Severity

Adjustable Alarmlimits

Trip relay

Bearing & Vibration ModulesCMM

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CMM Shock Pulse Module

Vibration Module

Temperature Module

4-20 mA output

Display

Rack Mounted ModulesCMR

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CMR

Shock PulseModule

Vibration Module

TemperatureModule

4-20 mA output

Display

Vibration

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Machine Guard MG-4

2 ch VIB, 2 ch SPM

Automatic Condition

4-20 mA & Relay

output

Online Diagnostic SystemCMS BMS & VCM

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CMS: BMS & VCM

Measure: Overall

Vibration

Vibration

Analysis Speed

Shock Pulse

Temperature

Total Plant Online

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Total Plant Online

Ferrography WPA Lab

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Ferrography WPA Lab

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Software

logger and OnlineM it i S t

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Monitoring System

Plant Condition in Software

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Plant Condition in Software

Machine Condition inS ft

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Software

Detailed condition in G Y R

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Detailed condition in G-Y-R

60

50

40

30

20

100

1000

Hz

Rotation

al

forcesVel

Acc

Shock

Cresr

Kurt

Skew

Friction

NL1

NL2

NL3

NL4

Symptom

s

Gearmesh

Unbalance

Misalignment

Vibration Spectrum inS ft

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Software

Features of Software

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Features of Software

Graphical overview Data storage Trends Analysis Alarm list Work orders Fault statistics

Reports Import / Export

CBT Software Vibration

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CBT Software - Vibration

iLearn Vibration Reference Centre

Case Histories

Virtual Test Rig

Signaldemonstrator

Machine modeler

CBT Software Alignment

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CBT Software - Alignment

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Services

Ferrography Report

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Ferrography Report

Ferrography Case Study

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Ferrography Case Study

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Case 1

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Case 1

Equipment: Thermal Shield FanCompany: RAPS

Unbalance identified

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Unbalance identified

After Balancing

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After Balancing

Before & After Balancing

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Before & After Balancing

Case 2

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Case 2

Shock Pulse AnalysisBearingCondition

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Condition

Unbalance Identified

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Unbalance Identified

After Balancing

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After Balancing

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