Online

Condition Monitoring
of Critical Machines
Contents

Objective

Background

Predictive Maintenance

Equipment Criticality

Recommendations for Critical Equipment

Implementation Phases
Objective

A SAFE and RELIABLE Plant

IMPROVED
PREDICTIVE CRITICAL IMPENDING
Through of MACHINES by early detection of FAILURE
MAINTENANCE
Background

GT-2101 A BL-1503 CE-1H

Failure Failure Failure

Intermittent Catastrophic Catastrophic
High Vibration Impeller Failure due Gearbox Failure
Tripping to High Vibration
Potential to Failure Curve
Predictive Maintenance Components

Protection
To protect machine from catastrophic
failure.

Monitoring
Diagnostics
To measure deviation
from normal values. To establish health
of machines and
predict its remaining
useful life
Detection and Prediction Failures

GT-2101 A 40%

Online Monitoring
Protection BL-1503
Diagnostics Online Monitoring
Protection
CE-1H Diagnostics
Online Monitoring
Protection Gaps in Predictive
Diagnostics
Maintenance for Critical
Machines
Equipment Criticality

SAFETY
1

REDUNDANCY 3 2 PRODUCTION

MTBF 5 4 MTTR
Equipment Criticality Classes

T
512

A B C

47 A* 86 78 348 9
Class A* Equipment

21
PVC

15
UTY & PP

4
EVCM

7
CA

Pumps = 14 , Comp/Blower/Fan = 25, Turbines = 3 & Centrifuge = 4

Gap Analysis and
their Solutions
11
 Turbines (GT-2101 A/B, ST-2301 & GE-8801)
Monitoring
Online Monitoring of all
Existing Practice critical parameters
No Gap Voltage
Gaps/Challenges measurement for bearing
clearance measurement
Gap Voltages to be
Recommendations measured when machine is
shutdown
Better Judgement call whether to Skip/Execute Maintenance Cycle on Time and Plan it accordingly as per
Benefits
Solution
Protection System Diagnostics
1
Offline Diagnostics using ADRE
Pre-set Alarms and Tripping
at 2 Months frequency.
based on those parameters.
Offline Oil Analysis.
Only shows health of machine at particular
instant. Difficult to predict remaining useful
No Gaps life of machine.
Gaps In
Online continuous diagnostics to detect developing
Existing
failures in real time. System 1 to be installed.
No System
Recommendations Online Oil Sensors to be installed.
Production Requirements.
 Fuel Gas Compressor (C-2410)

Solution
Monitoring Protection System Diagnostics
1

Offline Diagnostics using

Online Monitoring of Pre-set Alarms and Tripping
Windrock Assessment Tool.
Existing Practice Bearing Temperatures. based on those parameters.
Offline Oil Analysis.
No Monitoring for valve
Gaps/ No protection based
temperatures, Piston Rod Drop and No online Diagnostics.
on valve temperature
Challenges Deflection, and methane detection.
Gaps In
Existing Online Diagnostics Package for Reciprocating
Recommendations Eddy Current Probes, RTDs and Protection to be set on Compressors to be installed.
Gas Detectors to be installed. System
valve temperature. To be incorporated to System 1 in future.

Benefits Will Allow to Prolong Maintenance Cycle by having an accurate image of health of critical components.
 Chlorine Gas Compressor (C-1460)

Solution
Monitoring Protection System Diagnostics
1

Online Monitoring of all Pre-set Alarms and Tripping

Offline Oil Analysis.
Existing Practice critical parameters. based on those parameters.

No Gap Voltage Not accurate assessment of machine internal

Gaps/ measurement for bearing health especially bearing conditions.
Challenges clearance measurement No Gaps
Depends on Physical Inspection.
Gaps In
Gap Voltages to be Existing Online Diagnostics or at least BNC connectors
Recommendations measured when machine is installation in existing system for Offline Diagnostics
System
No Recommendations using CSI or ADRE. (Cost 1 Mn PKR)
shutdown

Benefits Will Allow to make better health assessment of Rotor as its detailed inspection has never been carried out.
 Reactor Air Compressor (PC-201)
Monitoring
Casing Vibration are
Existing Practice taken.
Shaft Vibrations are not
Gaps/ taken which are true
Challenges indicative of health.
Permanent Proximity
Recommendations Probes and RTDs to be
installed.
Benefits Will Protect Critical Machine from Catastrophic Failure and Prevent Unscheduled Down time.
Solution
Protection System Diagnostics
1
High Amps and Lube Oil Offline Oil Analysis
Temperature.
No Protections based on No assessment of machine internal health
bearing temperature and especially bearing conditions. Depends on
vibrations. Physical Inspection. Difficult to find root cause.
Gaps In
Pre-set Alarms and
Existing Online Diagnostics Software to be
Tripping based on bearing purchased alongside hardware.
System Approx. Cost
vibration and temperature.
 Centrifuges (CE 1H/2H, CE-1501 A/B)

Solution
Monitoring Protection System Diagnostics
1

Offline Bearing Vibration

Offline Diagnostics using CSI.
and Temperature High Amps and Over Torque.
Existing Practice Offline Oil Analysis.
Monitoring.
No continuous monitoring
of PVC I-II Gearbox Temp. No Protections based on No Diagnosis for PVC-II Gearbox
Gaps/
No vibration sensor on Gearbox Temperature. Oil due to Bath Lubrication.
Challenges torque assembly PVC II Gaps In
IR Thermometers, RTDs Protections
Existingto be set for Permanent/Wireless Accelerometers
Recommendations vibration sensor to be PVC I-II Gearboxes based to be installed for online diagnostics.
installed.
System
on oil temperature.
Gear box temperature monitoring and protection will Protect Expensive Critical Machine Component
Benefits (Gearbox) from Catastrophic Failure.
 Pumps/Blowers/Compressors/Fans
Anti-Friction Bearings

Solution
Monitoring Protection System Diagnostics
1

Offline Bearing Vibration Offline Diagnostics using

High Amps. CSI/Vibropen
and Temperature
Existing Practice Monitoring. Offline Oil Analysis.

Gaps/ May miss out exact event Does not cover protection Difficult to form correlations with
which created failure. for all equipment functional process parameters for RCA.
Challenges failure modes.
Gaps In
Permanent/Wireless Pre-Set Alarms and Online Diagnostics to be done for
Existing
Recommendations Accelerometers to be installed Tripping for Bearing detecting failure during developing stage
for continuous monitoring. TemperatureSystemand Vibration. (Approx. Cost 0.5 -1.5 Mn PKR)

Benefits Will Protect Critical Machines from Catastrophic Failure.

Benefits

Optimize Better
Inventory Prognostics

Longer Better Health

Maintenance Cycle Assessment
Phases

Power Plant Utility CA

02 04

01 03 05

PVC VCM
References
• API Standard 670: Machinery Protection Systems. Fourth Edition. December 2000.
• ISO 14224:2016: Petroleum, petrochemical and natural gas industries – Collection and exchange of
reliability and maintenance data for equipment.
• Charles T, Hatch (2002). Fundamentals of Rotating Machine Diagnostics. Bently Nevada Press.
• Sharma, “ Vibration Monitoring Identifies Steam Turbine Seal Rub”.
• Periyaiya, “Feasibility Study of Installing Online Vibration Monitoring and Analysis System in an LNG
Plant (GE System 1).
• Jaderi, Ibrahim, Jaafarzadeh, Abdullah, Yavari, Shamsudin & Nabavi, “Criticality Analysis Using a Risk
Assessment Based Maintenance of a Petrochemical Company.”
THANK YOU
Questions ?
ANNEXURE
Equipment Criticality Matrix

Average >1 2
Extremely High Production Stop 8
Good F=1 1.5
High Impact Production Levels 6 Excellent <1 1
Average Operational Disturbance 2
Low No loss of Production 1
High SCD 8
Low NSCD 0
High MTTR > 5 Days 2
Average 3 Day > MTTR < 5 Days 1.5
Low MTTR < 3 Days 1

Asset Criticality Level Risk Value

High Standalone and requires 24/7 Availability 4
Critical R >= 30
Standalone but doesn’t require 24/7
Average 2 Semi-Critical 15> = R <30
Availability
Low Standby 1 Non- Critical R < 15
Class B Equipment Filtration

If an equipment having anti-friction bearing doesn’t

1 Class B
have bearing failure in the past.
If the equipment running is subjective to need. Example
2 Class B
DEGs.
3 If it is a small positive displacement dosing pump. Class B
4 If the equipment is low rpm machine. Class B
If the equipment runs for very short duration in a
5 Class B
month
Class A* Equipment List
S.No Equipment Tag Equipment Description Plant
Turbines
1 GT-2101 A/B Gas Turbine (Hitachi) PP
2 ST-2301 Steam Turbine PP
3 GE-8801 Gas Turbine (Tornado) Uty 1
Pumps
1 PU-1104 VCM Feed Pump PVC 1
2 PU-1106 VCM Transfer Pump PVC 1
3 PU-1401 1st Recovery Compressor Seal Water Pump PVC 1
4 PU-1402 2nd Recovery Compressor Seal Water Pump PVC 1
5 PU-1801 Vacuum Pump Seal Water Pump PVC 1
6 PU-1802 VCM Compressor Seal Water Pump PVC 1
Class A* Equipment List
S.No Equipment Tag Equipment Description Plant
7 PP-407 A/B Cracking Furnace Feed Pump VCM
8 P-1484 A/B Hypo Primary Pump CA
9 P-1485 Primary Hypo Cooling Pump CA
10 P-6101 Molten Salt Pump CA
11 PU-8401 A/B/C/D/E Cooling Water Pump Uty 1
12 P-4302 A/B Raw Water Pump Uty 1
13 P-4402 A/B/C/D/E/F Cooling Water Supply Pump Uty 2
14 PU-8402 A/B/C Chilled Water Pump Uty 2
Blowers/Fans/Compressors
1 BL-1302 Ventilation Blower PVC 1
2 BL-1503 Dryer Exhaust PVC 1
3 BL-1601 Conveyor Blower PVC I
4 CO-1401 1st Recovery Compressor PVC I
Class A* Equipment List
S.No Equipment Tag Equipment Description Plant
5 CO-1402 2nd Recovery Compressor PVC 1
6 CO-1801 Vacuum Pump PVC 1
7 CO-1802 VCM Recovery Compressor PVC 1
8 RF-1701 Raw Water Chiller PVC 1
9 BL-2H Dryer Blower PVC II
10 BL-3H Dryer Exhaust Blower PVC II
11 C-101 Pneuma Blower PVC II
12 GR-212 Glycol Chiller VCM
13 GR-301 HCL Chiller VCM
14 PC-201 Reactor Air Compressor VCM
15 C-1460 Chlorine Gas Compressor CA
16 C-4252 A/B Refrigerant Compressor CA
Class A* Equipment List
S.No Equipment Tag Equipment Description Plant
17 BL-6101 Combustion Air Fan CA
18 BL-4101 Exhaust Air Fan CA
19 CO-8802 Fuel Gas Compressor Tornado Uty 1
20 SP-8401 A/B Cooling Tower Fan Uty 1
21 C-9001 A/B EPEX Chiller Uty 1
22 B-4420 A/B/C/D/E Cooling Tower Fan Uty 2
23 C-2410 A/B Fuel Gas Compressor (Hitachi) PP
24 C-2501 A/B/C/D ECAN Chillers PP
25 S-2119 A/B/C/D Turbine Compartment Ventilation Fan PP
Centrifuges
1 CE-1501 A Centrifuge PVC 1
2 CE-1501 B Centrifuge PVC 1
3 CE-1H Centrifuge PVC II
4 CE-1H Centrifuge PVC II
System 1 Requirements

• ST-2301
•
•
GT-2101 A
GT-2101 B
10 Mn PKR
• GE-8801

Common for All.

License to be
purchased for each.
20 Mn PKR

Total Costing = (10x3)+20 = 50 Mn PKR

System 1 Benchmarking
Costing -- PVC

S.No Equipment Bently Nevada (MPKR) Any Other (MPKR)

1 Pumps/Compressors/Fans/Blowers 1.5 x 21 0.7 x 21
31.5 14.7
IR Thermometer and RTDs on Centrifuges
Instrument Cost (MPKR)
1 IR Thermometer 0.5 x 2 = 1
2 RTDs 0.5 x 2 = 1
1+1=2
Total
2 + 31.5 = 33.5 MPKR (Bently Nevada)
2 + 14.7 = 16.7 MPKR
Costing -- CA

S.No Equipment Bently Nevada (MPKR) Any Other (MPKR)

1 Pumps/Compressors/Fans/Blowers 1.5 x 6 0.7 x 6
9 4.2
IR Thermometer and RTDs on Centrifuges
Instrument Cost (MPKR)
1 BNC Connectors 1
2 System 1 for C-1460 20
Total
20 (System 1 for C-1460) + 9 = 29 MPKR
1 + 4.2 = 5.2 MPKR
Costing – Utillities and PP

S.No Equipment Bently Nevada (MPKR) Any Other (MPKR)

1 Pumps/Compressors/Fans/Blowers 1.5 x 10 0.7 x 10
15 7
2 FGC – Hitachi 4
3 System 1 + Misc 20
4 3500 Rack for Tornado 10
5 3500 Rack for GT-2101 A/B 20
Total
50 + 4 + 15 = 69 MPKR
50 + 4 + 7 = 61 MPKR
Costing – VCM

S.No Equipment Bently Nevada (MPKR) Any Other (MPKR)

1 Pumps/Compressors/Fans/Blowers 1.5 x 3 0.7 x 3
4.5 2.1
2 PC-201 30 MPKR
Total
4.5 + 30 = 34.5 MPKR
2.1 + 30 = 32.1 MPKR
Bathtub Curve