Emerson Process Management - CSI

DoctorKnow Application Paper

Title: Considerations for Multi-Plant Vibration Monitoring Program Source/ E.R. Bradbury Author: Product: General Technology: Vibration Classification: Considerations for a Multi-Plant Vibration Monitoring Program E. R. Bradbury Praxair, Incorporated Tonawanda, NY About the author Gene Bradbury is a Vibration Analysis Consultant at the Praxair Technology Center in Tonawanda, New York. In eighteen years with Praxair, Incorporated (formerly known as Linde Division of Union Carbide Corporation), his responsibilities have included analytical and experimental stress analysis, computer assisted analysis and testing, and the development of remote vibration monitoring systems. He has been involved in the vibration analysis of high speed turbomachinery for over twelve years and played a significant role in planning and implementing the nationwide vibration monitoring system at Praxair. Mr. Bradbury received a 8S in Engineering Mechanics from Pennsylvania State University in 1975. Abstract In the mid 1980's, Praxair Incorporated began to implement a nationwide condition monitoring strategy. The initial step of this effort consisted of augmenting the vibration monitoring capabilities at facilities all over the country and then consolidating the individual plants into a comprehensive vibration analysis network. Currently, more than one hundred domestic plant sites participate in the vibration analysis program that forms the basis for this paper. Introduction Although Praxair (known as Linde Division of Union Carbide Corporation until June 1992) has been active in the vibration analysis community for close to forty years, the 1990's ushered in several new opportunities. New maintenance philosophies, new tools for equipment monitoring, new diagnostic techniques, and computer-assisted analysis software programs are changing the face of the industry. The availability of this new technology prompts a review of the methods used to acquire, process, analyze, interpret, and even report vibration data. Like many other companies in this time of innovation, Praxair found itself reviewing its vibration analysis practices. In the decades after World War II, maintenance philosophy gradually evolved from a reactive
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mode (run-until-it-breaks) to calendar-based preventive maintenance. By the early 1970's, literature [1,2] began to document the cost-savings potential of predictive maintenance - a new philosophy asserting that monitoring the condition (or health) of operating machinery gives an early indication of impending problems and is therefore a valuable tool for determining and scheduling appropriate maintenance activities. Industry rapidly adopted the concepts of predictive maintenance. Success stories and testimonials have populated trade magazines and professional meetings ever since. A good vibration monitoring program is the cornerstone of most predictive maintenance programs. Properly implemented and run, such a program will yield benefits such as improved machine reliability, longer production runs, shorter downtime, and general profitability in terms of reduced maintenance costs and increased productivity. Successful implementation requires management support, commitment of the necessary resources, well-trained personnel dedicated to the vibration surveillance program, good organization, and good record keeping practices. Programs lacking these ingredients are frequently doomed to failure. Air Separation Industry Praxair, a world leader in air separation and purification techniques, is the largest industrial gases supplier in North and South America, and has plants located all over the world. More than one hundred facilities are strategically located across the United States to achieve an effective distribution network. While these facilities are common in purpose, they vary significantly in process, equipment, physical size, and staffing. The complexion of the air separation industry is unique among major chemical businesses in many ways. Air separation plants are typically smaller, both in physical dimensions and in the amount of mechanical equipment present. Because on-site staffs are small, plant personnel are expected to develop a diverse range of skills, limiting the time available for specialization in any single area, such as vibration analysis. The basic raw material, air, is free, although significant amounts of energy are consumed in the process of separating and purifying the air into its constituents: nitrogen, oxygen, argon, etc. The most familiar process involves the use of compressors and expansion turbines to achieve refrigeration, liquefaction, and separation of the air. Other processes are also used and a few facilities utilize an offgas or byproduct of another industry as the feed stream. At a given location, plant design and equipment selection is dependent upon the quantity and quality of the product required. In addition, plant designs have changed over the years as new processes were developed and as improvements in compression and expansion equipment became available. As a result, on a nationwide basis, Praxair owns and operates a wide variety of equipment ranging in size from less than 100 HP to greater than 35,000 HP. A typical facility operates 24 hours per day, 365 days per year. Major pieces of equipment are not spared and when unexpected equipment failures occur, they can result in plant downtime. A highly effective condition monitoring program can provide the information required to maintain the operating equipment and plan for the future maintenance activities.

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Praxair's Old Vibration Program As a whole, Praxair plants run well; on-stream rates are relatively high, exceeding 95%. A portion of the credit for this fact goes to the specifying engineering staff. A set of carefully defined, detailed specifications, including vibration limits, has helped control the quality of equipment purchased for use in Praxair plants. Credit also goes to the operations staff, who effectively monitor and run the equipment on a daily basis. A preventive maintenance program has been in place on all major equipment for many years. At regular intervals, each machine was taken apart, certain components were replaced (regardless of their condition), and the machine was reassembled. While this approach represented an improvement over reactive maintenance philosophy, the required downtime, materials, and labor were expensive, especially if the machine was "healthy". Furthermore, the procedure subjected the equipment to the possibility of sustaining damage during the "repair" procedure or due to incorrect reassembly. [Studies in the commercial aircraft industry [3] showed that most failures were not calendar related, and that there was an unusually high correlation between failures and recently performed maintenance work!] Virtually every major piece of rotating equipment in the Praxair system has been purchased with permanently installed Bently-Nevada [B/N] proximity probes. Although these probes were installed primarily for machinery protection, it has been standard operating procedure to log the overall vibration levels, as indicated on the B/N monitor. Plant maintenance personnel began to regard the B/N monitoring system as an accurate barometer of machinery condition. In essence, many plants were utilizing a form of predictive maintenance. As spectral analysis tools became readily available, vibration practitioners began using the B/N probes to gain insight into the machine's health. Routine vibration data collection and analysis was performed at many plant sites by roaming experts who visited on a periodic basis (typically 2-4 times per year). Spectral data was recorded on paper and sometimes on magnetic tape for comparison to previous data sets. Between visits, plant operations would rely heavily upon permanently installed B/N proximity probes to identify changes in the overall vibration levels of the major pieces of rotating equipment. If changes were observed, the vibration experts were called in to survey the situation. All in all, the existing program suffered from several deficiencies.
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Spectra were acquired infrequently; the interval between spectra was too long for good trending. Changes due to seasonal variation or weather conditions could not be separated from a true change in the behavior of the machine. Rapidly developing situations were often missed entirely. Early identification of problems occurred more by chance than by plan. Furthermore, much plant equipment was reaching advanced ages on the bathtub-shaped life cycle curves, and there is anticipation that the number of failures would soon begin to increase. Manpower resources were not being used effectively. Highly trained vibration analysts were spending more time traveling between plant sites than analyzing vibrations. Once at a site, most of their time was spent gathering data from good machines, instead of analyzing

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data and solving machinery problems.

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Prox probe data portrays a limited view of the total machinery health picture. While the proximity probes accurately monitored rotordynamic-related problems and other low frequency phenomena, the location and the frequency response characteristics of these displacement transducers simply did not facilitate the acquisition of high frequency phenomena, such as gearmesh activity. Plant personnel had neither the tools nor the training to acquire and analyze accelerometer data accurately. And moreover, the data management could have been much more effective. Although duplicate machinery existed at plants located in different regions of the country, vibration data and machinery histories were not shared. Vibration data were taken at different measurement points, using different tools, and different spectral parameters. For example, one group of vibration analysts routinely used peak hold spectra, while another group used summation averaging. As mentioned before, several studies have been published supporting the conviction that predictive maintenance philosophy represents a significant opportunity to reduce overall maintenance COSTS. In one recent EPRI study [3], normalized costs for the three maintenance philosophies were compared in terms of dollars per horsepower per year ($/HP/ year). Reactive mode costs were estimated at $17-18, preventive maintenance was $1 1-13, while predictive maintenance was just $7-8/HP/year.

For all of these reasons, full implementation of a predictive program was preferable to pure preventive or the hybrid mixture of programs being used. It was decided that Praxair would pursue the transition to a system-wide condition monitoring / predictive maintenance program. Simply stated, the goals would be to reduce costs and improve profitability by early detection of impending problems, increasing the interval between turnarounds, and improving problem analysis, diagnosis, and correction capabilities by sharing information in an equipment database. Overview of the New Program The planners of the new vibration monitoring program envisioned a network of independent plants sharing support and advanced analysis resources, Each plant would collect and use its own vibration data and then share the information with the rest of the network through a "national database", To facilitate this plan, several global decisions were made to provide a uniform structure for the vibration monitoring program at each plant location, As an example, the instrumentation and analysis software was evaluated by a team of vibration experts and plant maintenance personnel. Their group recommendation defined the universal hardware and software selection for every plant in the network. Several direct benefits include: improved data interchangeability, simplification of support issues, alignment of efforts, improved interplant communication about vibration issues, a single set of evaluation and development costs, and last, but certainly not least, the ability to take advantage of quantity price breaks.

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In a similar fashion, conventions regarding measurement location and nomenclature were adopted. As a result, measurement points on identical machines at different plant sites were positioned at the same spot and identified with the same name, permitting easy comparison of vibration data. A generic template consisting of common machinery types was created to facilitate expedient and uniform database construction. Analysis parameter sets and alarm limit sets applicable to the wide range of equipment were built into that template. At each plant facility, a vibration "partner" was selected to "champion" the program, Since this individual was not a vibration analyst, the tools end procedures for vibration collection and analysis had to be straightforward and as simple as possible, At a one week, in-house seminar, the partner would be instructed in vibration basics 'as well as appropriate use of the data collection and analysis tools, Another consideration was to ensure that the selected instrumentation had sufficient capability to permit individual growth and continued development of skills in vibration analysis. It was anticipated that as the partners became familiar with this exciting technology, a few would be interested in pursuing additional vibration expertise. With the proper support and encouragement, this path could lead these individuals to become the vibration analysts and program leaders in the future. The establishment of a central support organization was another key element of the program. The charter of this group includes the upfront engineering work, consultation on vibration problems, cataloging of problems to identify chronic equipment deficiencies, working with the equipment suppliers to resolve those chronic problems, monitoring the success and profitability of the program, channeling design feedback to the system engineers, training the plant partners, and resolving equipment and software questions of both new and experienced partners. To facilitate communication from the plant partners to the vibration experts, a telephone "helpline" was dedicated to assist in the resolution of vibration questions and problems. The transition from the existing state to the desired state progressed in phases. First, program needs were weighed against financial considerations to identify an appropriate choice for the new vibration monitoring platform. Next vibration experts and plant maintenance personnel worked together to evaluate the commercially available tools and identify acceptable instrumentation. The purchasing team began to negotiate quantity pricing contracts with the instrumentation suppliers. The vibration experts also investigated the selected tools in depth and began to identify optimal implementation and utilization methods. After these preliminaries were all in place, implementation at the plant sites was started. Care was taken to guarantee that during the implementation stage, the appropriate training and support were provided to assure an orderly transition. Details on each of these steps is provided in the following sections. Selection of a New Vibration Measurement Platform Today's assortment of analysis equipment and techniques provides a formidable arsenal for the vibration professional reassessing the condition monitoring program at his location. The current generation of high technology instrumentation offers excellent monitoring and analysis capability
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in conveniently sized packages at relatively affordable prices. One popular tool for providing monitoring and analysis capability at an affordable price is the portable vibration data collector. Used in conjunction with analysis and trending software on a personal computer, this instrumentation provides a versatile range of capability at an affordable price, yet it is simple enough to use without years of training and experience. The specifications of the portable machinery analyzers on the market today rival those of standalone spectrum analyzers; averaged spectra with 400 or more lines of resolution can be obtained at frequency ranges up to and surpassing 20 kHz. Used in route mode, the users can advance from measurement point to measurement point while the device automatically controls all of the digital signal analysis variables to assure that data taken at each defined measurement location is consistent with previous data. The devices also possess the ability to store spectra and waveforms from hundreds of measurement points - a function formerly handled by analog instrumentation tape recorders and/or reams of plotter paper. Built-in battery features protect against the loss of data. In addition, the hardware facilitates transferring the newly acquired vibration data to a personal computer for subsequent analysis, trending, and reporting. For the program envisioned, a portable data collector used in conjunction with personal computer analysis software seemed an appropriate solution. Features such as spectra and waveform displays, phase analysis capability, and the ability to run special downloadable programs were highly desirable to help assure that the portable data collector would not inhibit the growth of the partners in the first five years. The personal computer platform offered connectivity and access to database programs, spreadsheets, word processing packages, etc. Selection of a Data Collection System and Software A three phase study of six portable vibration data collectors was undertaken in the third quarter of 1986. First, the evaluation team met with each of six equipment manufacturers for a detailed review of capabilities and basic training on the use of each product. The units were subsequently subjected to a field evaluation test at a Praxair production facility. The third and final phase consisted of a software comparison of the qualifying packages to determine differences in both quality and content. A detailed spreadsheet was used to organize the data and evaluate the relative performance. The hardware was judged in four general categories: Technical Specs (electronics, storage capacity, frequency response, FFT specifics), Design(physical, environmental,battery system, ergonomics), Functionality (legibility, keypad layout and feel, user friendliness, and input sensors), and Evaluation in Use (ease fo use, features, local diagnostics, and field performance). Each of the subcategories listed above was further broken down, and the hardware was graded on a total of about 150 separate items. Each subcategory was assigned an appropriate weighting factor, and a grand total was determined on a scale of 0 to 100. A similar approach was used to evaluate the software. The four general categories included: Software capability (reports, spectral displays, trends, other features), Software use (user friendliness, intuitive procedures, speed, adaptability), Computer hardware (memory and hard disk requirements for program, video compatibility, database file requirements), and Support (confidence factor, problem resolution, upgrade policy, training). As with the hardware, the
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subcategories were further broken down, individual items were graded, weighted, and contributed to a composite score from 0 to 100. The systems were ranked in order of their cumulative scores and one system was purchased from the top-rated supplier for a plant pilot study. It was believed that any of the three best-scoring systems could be successfully used to implement the envisioned condition monitoring program, so the purchasing team began negotiating quantity pricing with all three contenders. By December of 1988, when the pilot study was completed, there had been so much change and improvement in the marketplace, another evaluation was undertaken. [It is pleasant to note that the manufacturers had corrected most of the deficiencies which had been identified during the first round of tests.] Interestingly, the finish order of the new study included the same three manufacturers in the same order, but all scores were higher than the first time around and the spread between the manufacturers was not as great. It is also noted that the products of all three of manufacturers are still present in market today. Consistent Implementation at all Plants Implementation strategy at a plant site was designed to be relatively transparent to the plant. A small team of vibration experts was responsible for an initial assessment of the plant to determine measurement locations and set up the database. Another team installed accelerometer measurement targets [4] to prepare the plant for data collection in a manner that would assure repeatable, accurate data. At about the same time, the plant partners were scheduled to attend a one week inhouse training session. Individuals would receive the vibration analysis tools during training where they would be taught why, where, and how to use the tool effectively. Many of the steps toward uniformity and consistency helped to assure that the usual start-up frustrations and mistakes would be eliminated, or at least kept to a minimum. Implementation and execution at the plant were simplified and there was confidence that the machinery measurement points were defined appropriately and consistently at all plants in the network, each plant database was set up properly and consistently, and the plant partner was properly trained, equipped and ready to begin acquiring valid data immediately. The size of the total system and the limitation on resources made it necessary to utilize a staged implement scheme, activating five or six plants at a time. In actuality this was a blessing, since the telephone helpline activity soared for two to four weeks immediately following each training session. After that initial surge, as the partners began to first exercise their newly developed skills, telephone support activity would return to normal. Central Support Services The objectives of the central support organization are detailed in a previous section. The group continues to handle issues that have a global impact upon the program. A few examples are detailed below. As mentioned before, the central support organization provides a one-week in-house training session for each plant participant in the program. Utilizing in-house training provides the opportunity to tailor the experience to specifically address the vibration monitoring program and
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maximize the productivity of the sessions. As an example, most similar introductory courses include several hours of instruction on how to effectively set up analysis parameters and alarm limit sets. Since experienced vibration experts preset the vibration parameters on each measurement point at the plant, the concept is covered briefly and the time is utilized to cover other topics of significance. In addition to practicing on rotor kits and other vibration instruction tools, training includes a half-day of data acquisition at an operating Praxair plant. Commercially offered courses have satisfied the needs for additional training, although an advanced training program is being developed in-house to address the continuing needs of our vibration partners. The "vibration helpline" telephone line continues to ring and it has proved to be an effective support tool for the program partners. In addition, the Praxair Maintenance Newsletter is used to disseminate information, provide further education on new techniques, and celebrate success stories. Unsolved problems from each location are escalated to regional and then to the national center where the pool of vibration analysis experience and machinery maintenance knowledge exist. In essence, a tiered vibration support ladder exists, wherein problems are solved at the appropriate level of expertise. Difficult problems rise to the top of the ladder where support is available for even the most unusual problems. Databases from each location funnel into the national centers where the information is rearranged so that similar machines at different locations can be compared on a national basis. This concept, the national database, is currently being implemented. Other challenges currently being reviewed and planned in the Central Support Organization include decisions on ISO standards and calibration issues. Concluding Remarks The methodology used to implement and support the vibration monitoring network described in this paper has worked well at Praxair. While the particular circumstances that exist make every installation unique, a few key observations may be drawn from this experience.
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Select tools that will make You successful, today and tomorrow. When deciding on vibration analysis tools, plan for the future. Do not limit potential growth by buying solely on today's needs, but rather anticipate tomorrow and purchase enough capability to bridge to the future. Plan the implementation phase carefully.

Decisions on how to collect and manage data should be made early, focusing upon the desired output of the program. This planning will both simplify implementation and maximize the value of the program.
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Utilize a vibration expert.

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Years of vibration experience and judgment are required to proper/y implement a new vibration program. If that talent is available in-house, use it; otherwise, purchase it. Many instrumentation suppliers either offer start up services or can recommend an independent who can do the job properly.
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Strive for continuous improvement.

Our system is nearly fully implemented, but the work list is now longer than when we started. With each successfully completed challenge comes additional new and exciting opportunities.
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Enjoy the work.

The vibration industry is based upon a vibrant, rapidly changing technology. The work is exciting, challenging, worthwhile, enjoyable, and gratifying. Enjoy it. References Hudachek, R. J. and Dodd, V. R., "Refinery-machinery surveillance and diagnostic program pay off", Oil and Gas Journal, Oct. 18, 1976, pg. 70-81. Blotzo, C., "Machinery Monitoring is Well Justified", Oil and Gas Journal, Nov. 22, 1976, pg. 144147. Wowk, Victor, Machinery Vibration Measurements and Analysis, McGraw-Hill Inc., 1991. Bradbury, E.R., and Jowdy, G. G., "Collecting High Frequency Vibration Data for a Condition Monitoring Program", Vibration Institute Annual Meeting Proceedings, June, 1992. All contents copyright 1998 - 2006, Computational Systems, Inc. All Rights Reserved.

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