Condition Based Monitoring of Rotating Equipments

Presented By: Harshal Aglawe Sch. No. 132116203

Introduction
The condition of rotating machinery, including

motors, pumps and blowers, is commonly monitored by systems that record vibration levels. However, gathering this information in the field using portable equipment can be time consuming and labor-intensive, and once-a-month snapshots do not provide adequate coverage of essential equipment. Some vibration-monitoring systems continuously guard expensive equipment such as steam or gas turbines, generators and compressors that are critical to the uninterrupted operation of a facility.

What vibration analyst do?

A vibration analyst transmits the data to a central

location for study. When applied to pumps, vibration analysis is used to: Track progressive stages of bearing failure Identify imbalance and misalignment Identify pump flow problems and resonance Identify mechanical wear in couplings, bearings and support structures Detect other defects such as lube failure, soft foot and broken rotor bars.

Monitoring Methods
Faults generate specific vibration signatures.

The route-based and online vibration monitoring

methods are widely used. Industries actually need a reliable means of continuously monitoring a wide range of production machinery automatically. Which must be capable of assessing signs of trouble and warn personnel.

What is New???
An innovative and practical solution is now

available to meet the need for online monitoring of motor-pump trains (even in remote locations) that are essential to operations in refineries and petrochemical plants. Automated diagnostics packages provide the means to predict pump performance for improved maintenance. The utilization of digital automisation gives the prevention of unplanned shutdowns.

Automated analysis
Continuous monitoring with updates within 60

seconds so operators can react quickly Integration of machine health information with control systems Centralised problem-solving to eliminate excessive trips to the field Diagnostic information provided for decisionmaking rather than just raw data.

Operation al

Transmitter.
Monitors and automatically analyses AC induction o o o

motor-centrifugal pump trains Receive continuous inputs from; Tachometer readings for shaft speed, Motor flux inputs from a flux coil, Temperatures measured at the motor surface. Data collection is repeated every 25 seconds.

Embedded capability (Automisation)

By introducing embedded systems it is easier to

monitor the rotating machines continuously Earlier maintenance personnel were responsible for collection of data and report the results to operating personnel. The sensors are simply mounted on the machine for which it was designed, the device is located nearby, and the data generation and analytical functions are automatically deployed, with results communicated directly to the control system host.

Smart machine health management

Transforms complex rotating equipment data into

actionable information Integrates real-time diagnostics into process automation systems Empowers operators to improve plant availability and performance. An estimated 68% of machine failures occur following an outage but with continuous online monitoring it can be reduced by 90%.

Maintenance
Information captured by various advanced

technologies can be used to reduce maintenance costs, extend equipment life and increase overall plant reliability. Data delivered to their fingertips from advanced monitoring systems, operators and maintenance personnel can predict with reasonable accuracy when each pump, control valve or field instrument will next need maintenance. The idea of predictive maintenance is to service equipment in time to minimise physical deterioration and unexpected failures

Maintenance
Even more effective is a combination of predictive

and reliability-based maintenance. All machinery is prioritised in order of importance to the overall mission. Critically important equipment must be maintained for maximum reliability. Portable vibration analysers applied to rotating machinery, provide snapshots of a machines health at the time the data was manually collected.

Supporting technologies
The information could be accessed only in the field by

technicians connecting and operating handheld communicators and is uploaded to a maintenance department computer. But with the emergence of new and improved open communication protocols the way for the delivery of both process measurements and diagnostics via analog signals back to central locations is possible. Software is developed to capture the data being transmitted from shop floor to maintenance technicians. A new way to obtain and use information about conditions in the field without leaving the comfort and safety of the maintenance shop.

Supporting technologies
The data is processed, organised into a database

covering all instrumentation on a control network and present it on graphic display. Maintenance personnel are able to use this asset management software in a number of beneficial ways o Faster start-ups through easy device configuration, o Streamlined calibration and troubleshooting o Early warning alerts of deteriorating performance, preventing costly unscheduled shutdowns and initiating predictive maintenance practices o Automatic documentation of maintenance activities.

Benefits
Smart machinery health management is a

concept that extends digital plant architecture to all types of rotating equipment. improved performance of essential motor-pump trains. Apart from vibration monitoring program; it improves overall machinery health. Reliable field-based information readily available empowers operators to improve plant performance and warnings enable maintenance personnel to prevent unplanned downtime.