Critical Machinery Management

Sanjeev Kumar
Bently Nevada LLC
The Past Paradigm

• Machines are often protected but not always

managed optimally
• Can lead to reactive rather than proactive
activities (little time to plan)
• Machinery damage and resulting production loss
often more than anyone anticipated

2
 The New Paradigm: Machinery / Asset Management

Optimize equipment assets to:

• Maximize machine/asset availability

No unscheduled downtime

Minimize outage duration
• Reduce operation and maintenance costs
• Minimize Life Cycle Cost
• Reduce time to actionable information and root cause

Strike a business balance between optimal process output and

optimal asset support cost

3
Why PAM ….Proactive Maintenance Strategy
Information ~ Reliability Based
Organization & Availability Proactive

Data ~ Condition Based

A2 Predictive
(Effectiveness)

A1
Planned
Preventive
A Breakdown
B Reactive
Typically 40% reduction
in maintenance cost

Maintenance Cost Expenditures

(Efficiency)
4
 Data Review
Correlated
Process Data

Level 2 Data Acquisition Remote

and Display Access

Control System Protection System

Sensors

Level 1

Sensors
Why Manage Machinery
Protection Danger Level

Machine
Stress
Protection Alert Level

Reduced
Cost Decision
Time

Machinery Management
Alert Level

6
Time
7
 Decision Support

Data Acquisition
and Display Remote
Access

Control System Protection System

Sensors

Sensors
Why Manage Machinery
Protection Danger Level

Machine
Stress
Protection Alert Level

Cost Management below the Alert

Level …..

Machinery Management
Alert Level
Online proactive process adjustment
returns stress to normal levels
9
Time
Summary Perspective - The New Paradigm
Level 1
Machine Stress & Life Cycle Cost

Level 1 w/Off line data

Level 2 w/Process data

Level 3

10
Time
Plant / Machinery Asset Management…

Five-step process
• Collecting and correlating data from many
sources
• Converting data to actionable information
• Communicating to the right people
• Optimizing the system and or process
• Taking action

11
Basic Need – Best Practices Measurements
X-Y RADIAL VIBRATION

13
Why X-Y …

•Better Protection
•Enhanced Information for Machinery Management

14
Orbit Plot Can Show Preloads

(Misalignment)

Rare Common Rare

15
 Radial Position with X-Y

Proximity Probes are used in

the X-Y configuration to measure
radial vibration, the dc signal from
the transducer can be used to
indicate the radial position
of the rotor within the bearing

16
Average Shaft Centerline

(Not Orbit or Polar Plot)

3.0
Top

2.0
* 9500
* 9400
* 9200
* 8700
* 8000
1.0 7600
1200
*
*
*500 * 4500
*5500

0.0 * 300
-1.0 0.0 1.0

Amplitude 0.20 mils / div X to Y (CCW) Rotation

17
Orbit and Position Indicators of Preload

Y X
TN
RO

BEARING
CL Y = - 6.8 Vdc
Normal Orbit X = - 7.2 Vdc
and Position
AVERAGE
SHAFT C
L

Normal steady load downward, such as gravity.

18
Orbit and Position Indicators of Preload

Y X
AVERAGE
SHAFT CL
TN
RO

Abnormal Orbit and

Position

BEARING CL
Y = - 6.2 Vdc
X = - 5.8 Vdc

19
Shaft Centerline Plot Can Show Misalignment

Turbine
Generator
1 2 3 4

20
 Full Spectrum

21
Why Keyphasor®

22
Why Keyphasor®

23
Why Data Correlation

Data Correlation did not indicate anything wrong with process

24
 TM
What is System 1 ? Plant IT Architecture

System1™ CMMS Reliability Remote

Engineering Operations
Display
Clients

Plant Information Network Remote

Server Server Server

DAQ / DB DAQ / DB DAQ / DB

TM2000 TM2000

Wireless
Machine
Control Heat Exchanger DCS
Operator
3500
w/TDI Heat Exchanger

Process Control

25
Continuous Updates

• System 1™ Display
can receive data from
3500 Monitors via
TDI

26
What is an Enterprise ? Components of an Enterprise

•Enterprise
•Plant
•Train
•Group
•Machine
•Rotor
•Bearing
•Point
•Variable
27
 Observe Several Plants
Simultaneously

28
29
 SUPPORTING EVIDENCE – the data !
Asset Condition Trends
correlated on-line with Process Data

30
 Detailed Symptomatic Information!
Asset Condition Diagnosis with Dynamic Data

31
Watching & Analyzing Change

•Trend plots
•Waterfall plots
•Software Alarms with
multiple severity
levels
•Plot overlays

32
Bargraph Display

•Available for all static measurement

variables
•Displays current values only - as often
as they are collected
•Right click in a bargraph to display plots,
linked documents, event list, and other
information

33
Current Values Display

•Open current values display

from bargraph right-click
shortcut menu
•Displays the same current
values as bargraphs, only in a
list format

34
Tabular List

• For analysis, samples

can be listed instead
of plotted

• Vector samples
include both
amplitude and phase
information

35
Change Filtering

• Establishes which collected samples will be stored

• Settings are selectable for each measured variable

36
Process Trend Example

• What
happened
here?

37
Sample Filtered Plot

• Click the
black arrows
to display
data from
before or
after the
1000
samples
being shown

38
Trend Plots
The trend plot can indicate a small change in maximum, minimum, or
average values, before it becomes critical

39
Waterfall Plot

The waterfall
plot can also
indicate a
change that is
not yet critical

40
Acceptance Region Alarms

• Polar plots can then display the established

acceptance region boundaries

41
Software Alarm Setpoints

• Trend plots
can display
level alarm
setpoints
• Severity 1,
2, and 4
setpoints
shown

42
Reference Data Collection

• Collected at a particular time to provide

comparison for particular operating conditions
• Collected for all measurement points in the
selected Collection Group
43
Reference Data Types

• Slow Roll – should be taken at a rotor speed where

dynamic effects are insignificant
• Gap – should be taken with rotor stopped or at
slow roll, with machine at normal operating
temperature
• Waveform – contains many samples collected over
a very short time, so the signal waveform can be
shown graphically on an orbit or timebase plot
overlay

44
Displaying Plot Overlay

Once overlaid,
samples from
different times can
be compared
graphically

45
Root Cause Diagnosis

Data Interpretation for Root Cause

Diagnostics :
• Steady State Data,
• Transient Data,
• Process Data Correlation

46
The Orbit Timebase Plot

• This plot displays both the orbit and the Y and X

timebase plots for analysis
47
Evaluating Shaft Deflection Shape

1 2 3 4

“A”

1 2 3 4

“B”

48
Use Of Orbits For Shaft Deflection Shape Analysis

A B C D E F

Different Bearings, Same Speed

with Keyphasor® Marker.

49
 Spectrum Relationships

COMPLEX
WAVEFORM

AMPLITUDE
8X
6X
TIM 3X C Y
E EN
1X Q U
R E
F
A spectrum shows the frequency of a signal versus
its amplitude

50
 Full Spectrum

The full spectrum

provides forward &
reverse precession
frequency response

51
Plot Relationships

2.5
2xA
UP
Y

Amplitude: (mil pp/div)

2.0
+ + + + +

1.5
+ + + + +
2xB

+ + + + + X 1.0
B
+ + + + +
B 0.5
A
+ + + + +

B 0
A -1X 0 1X
Reverse Frequency Forward
2.0 mil/div X to Y (CCW) Rotation A Vibration (Orders) Vibration

POINT: Bearing 1 Vibration vertical

B A

A B

A POINT: Bearing 1 Vibration horizontal

1.0 mil/div X to Y (CCW) Rotation 5.00 ms/div 4935 rpm

52
 Shaft Average Centerline Plot
Top
3.0
• Different from Orbit
plot and Polar plot
2.0 • Dashed circle
*9500
* 9400 indicates limits of
*9200 bearing clearance
* 8700
* 8000
1.0 7600
1200
*
*
*500 * 4500
*5500

0.0 *300
-1.0 0.0 1.0
Amplitude 0.20 mils / div X to Y (CCW) Rotation

53
 1X Bode Plot
Slow Roll 180
Phase 240
300
Phase Lag
(degrees)
360
60
120
180 Slow Roll Vector
240
4 Amplitude: 1.0 mils
pp
(mils pp)

3
Phase: 225 Deg. Lag
2

Slow Roll 1
Amplitude
0
0 500 1000 1500 2000 2500 3000 3500 4000
rpm
Slow roll speed range (no dynamic data).
54
 1X Compensated Polar Plot

Direction of Mass
Unbalance
0°
Amplitude and Direction
of Response at Balance

N
Resonance

T
RO
2370
2310
* * *
* 2280 2385
*
2205 **2250 2405
2070 * 90° 2415
*
270° 300
* 90°
2430 * 90°
2445
3615* 2775 2460
*
* *
Amplitude and Direction *2505
2610*
of Response Above
Balance Resonance

4.0 mil pp Full Scale 180° X to Y (CCW) Rotation

55
Startup to Rub Condition

-2X -1X -0.5X 0.5X 1X

Machine Speed (krpm)

Reverse Forward
Frequency (kcpm)
56
Full Annular Rub During Shutdown

-2X -1X -0.5X 0.5X 1X

Machine Speed (krpm)

Reverse Forward
Frequency (kcpm)
57
X vs Y Plot Example

58
Multi-Variable Trend Example

59
Data or Actionable Information®

? VER L OA D

O
TA
D A
=
60
Data to Actionable Information®

What is it?
How Bad?

Where? End-Users expect Data and

Measurements should be turned into
plain language Advisories….
…...Actionable Information®

When?

What should I do?

61
 Under Severity 4
Operation Status Is Red and Flashing

62
 Event Manager displays
location of alarm

63
 How Bad?

What is it?

Event Manager displays

Decision Support Alarm Messages
Where?

When?

Do we have good data?

What should be done?

64
65
66
 RulePaks…a Knowledge Base
Pre-configured rule logic with advisory text for these machines and malfunctions:
– Reactor coolant pumps – Shaft bow
– Steam turbines – High synchronous vibration
– Pumps – Fluid induced instability
(whirl and whip)
– Industrial gas turbines
– Radial pre-load forces
– Mechanical drive steam turbines
(including misalignment)
– Generators/alternators
– Acceptance region violation
– Exciters
– Rotor rub
– Plant air compressors
– Loose rotating parts
– Centrifugal and axial compressors
– Compressor surge
– Electric motors (Synchronous/Induction)
– Electric motor non-uniform air
– Gearboxes gap
– Reciprocating compressors – Pump cavitation
– Wind turbines – High runout
– Boiler combustion – Gear mesh anomalies
– Industrial Gas Turbines specific
malfunctions..blade pass etc.
67
– Hydro Specific Rules
Smart Notifier

68
Actionable Information Server Provides:

Email/Pager/Phone Mail Notification on Events

Easy Configuration of Severity, Action and Detail for ALL
Events
Actionable Information Reporting on All Events

69
RuleDesk™

70
Event Manager

• Display all applicable events, including hardware

and software alarms.
71
 Journal Editor

• Use as Operations Log to capture important

information about a plant asset.
72
DOCUVIEW™ Links

• Create links to important documents.

73
DOCUVIEW™ Links

• Open linked documents

74
Capturing Corporate Knowledge

Knowledge Corporate & Plant

Knowledge
&&Understanding Approved Plans
Understanding

Action
Action Comm
Comm
+ Plan
Plan + Plan
Plan =

Actionable
• Rule based / editor – embed knowledge Information
• Use any system data + asset properties
• Calculate new variables
• Define Events and their severity

75
 Decision
Support

Dynamic Data
Reliability Data CMMS
Historian

DCS Man Machine

Interface
(MMI)

Control Network

RS 232/RS485 Hub
or Ethernet

Modbus Gateway or
3500 Integrator Device

Alarm Contacts
Power Generation Water Injection Compressors
Motor G
Gearbox

e
Industrial Gas Turbine Generator a
r
Motor b Compressor
o
x Machine Control System
 Evolution
Smart Notifier 00s Actionable
DCS Advisory Information Internet
E-Mail, CMMS CMMS, ERP
Text, Pager Documents
90s Decision
Logs / Journals
Rule Paks Support
End User DCS – real time
OEMs 80s Data Process Historian
GE - BN Acquisition xls, csv, data simulators
Consultant
70s Monitoring On-Line continuous

RCFA 60s On-Line scanning

f(x1, x2..) Measurements
FMEA Off-Line portable
f(x1, x2..)
PDA Inspection

Manual Entry

Machinery Diagnostic & Condition Based Maintenance Technology

 Serial-RS 485
RS 485
Serial RS 485

DCU
SRR2

H2
SRR 1 Serial RS 485
DCS
EPCC 3 EPCC 3 CCR/NHT/DHT DCS
EPCC 1
SRR3
DCU- 1nos Centrifugal Comp 16 Port Hub Ehernet Hub CCR/NHT/DHT
16 Port Hub Ehernet Hub
H2 - 1nos Reciprocating Comp with Fibre Optic Backbone 2nos Centrifugal Compressor, 8nos Reciprocating with Fibre Optic Backbone
compressors;
1200 Mts
1100 Mts 950 Mts

CENTRAL CONTROL ROOM(MCR)

4 Port Fibre Optic Hub with
AUI Backbone & conveter to
10 Base T

16 Port Hub Ehernet Hub

DCS
Process Data

Serial-RS 485
Serial 150 Mts
2nos Data Manager® 2000 & 16 Port Hub Ehernet Hub
DCS
HCU
EPCC 3 3500 Software Server EPCC 1 with Fibre Optic Backbone

HCU - 1nos Centrifugal Compressor; 4nos Reciprocating Compressor; 4nos Extraction Turbine

LEGEND
3500 Rack
PLANT WIDE MACHINERY Fibre Optic
PROTECTION, MONITORING & TDXnet Communications Processor
MANAGEMENT SYSTEM LAYOUT Ethernet
FOR HUB
EAST INDIA REFINERY,PARADEEP Serial

78
An example….A Refinery

79
An example….Power Plant

80
Machinery Management..Benefits and Cost Justification
The Machinery Management system shall provide excellent Return on
Investment
• Approx. 1.0% of total investment for a new Power Plant
• Investment in Machinery Condition Management System can
often be recovered during Commissioning period
– avoids delays in decision making
– eliminates machinery damage possibilities
– increases owner’s confidence
– acts as a machinery, installation quality check
– provides base line useable for life
– OEM gets to ratify machinery behaviour
– End-user feels comfortable to take over machine being
fully aware of its behaviour characteristics.

81
Machinery Management..Benefits and Cost Justification

During the life of the machinery the Machinery Management System

shall provide information which:
• Intelligent and well informed O&M decision making
– There is a machinery problem, but is so well identified
and understood that the machine can be continued to
run
• Highest load factor as well as no reduction in overall
life
– this is important factor with HP / IP turbines in all
situations

82
Machinery Management..Benefits and Cost Justification

Increased Generation through enhanced availability

• operate machines safely even when normal
operational limits are exceeded
–behaviour of the machine is fully understood
• reduce downtime required to solve machinery
problems
–problem has been identified & a solution has
been planned even before the shutdown is
taken.

83
Return on Investment

Sometimes “return” is not only financial.

• More job satisfaction; less stress.
• People feel they are in control, do a better job.
• Planning instead of reacting; no surprises.
• Eliminate need for fireproofing (since they now have no fires).
• When failures do occur (none are catastrophic), they know what
to fix, what parts will be needed, and how long it will take.
• Can make confident, conscious decision to “run to failure” if
necessary.
• Less overtime; fewer people required.
• If it ain’t broke, don’t fix it; less waste.

84
Business Problems A Machinery / Asset Management Solution
Solves

Captures Unexpected Events

• Machine Trip, Mis-Operation, Part Failure
• Answers Question “What Happened ?”
• Answers Question “Can We Continue Safely ?”
• Sequence Of Events
• Data Captured On Alarm

Provide actionable information for taking Pro-

active actions for Plant Asset Management.

85
Business Problems A Machinery / Asset Management Solution
Solves

On Site Expertise
• Remote Access For Product Specialist
• Move Data Not People
• Decision Support System 24 Hours/Day
• Early Warning Of Mechanical Integrity Change
• BNC Machinery Remote Diagnostics Contract

86
 a l
…….an Emergency Service scenario: A machine train
c
cannot be restarted following an outage, due to ihight.
o m n
vibration. n e
co ipm
e e u
r
o d eq
e m an
RE
PO or le
RT
m op
c h pe
u e
MODEM
m
s m o v
i
a to GE / BN
t
da ng
ng vi
v i a
o h
M an
th
87
Providing Results..Working on both sides of ROI equation
Increased safety
Conduct responsible care
Lowering maintenance costs
Production Support
• Improved maintenance

Cost ($)
personnel efficiency
• Fewer and smaller repairs =
• Less time based
maintenance (fewer Time
turnarounds)

Revenue ($)
Increasing machine Machinery Availability
availability/production capacity
– Expedited problem resolution =
– Less downtime Flexibility
– Greater machinery efficiency
– Extend periods between outages Time
88
 Thanks for your Time

89