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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.exe8/14/2019 Optimizing Condition Monitoring
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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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