Automated Machinery Automated Machinery MaintenanceMaintenanceBill Powell

Tony Burnett

AgendaAgendaAgendaAgenda Industry Trends & Challenges Machinery Health Strategy Automating Decision Support Key Points

The ‘Game’ of Plant Reliability - PlanningThe ‘Game’ of Plant Reliability - PlanningThe ‘Game’ of Plant Reliability - PlanningThe ‘Game’ of Plant Reliability - Planning

Planned Outage

ID Fault

Question: Can we make it to the next outage?Challenge: Track fault… ‘get us to Nov 20get us to Nov 20’Action: Alert Maintenance Planner

March 1

Nov 20

Nov 29

OUTAGE PLAN1. Change Bearing $$$2. Align Motor $$$3. Install New Coupling $$$… … … … … … … … …

Outa

geFailure

Planned Outage

Business MetricsBusiness MetricsBusiness MetricsBusiness Metrics

Areas that are impacted most by Predictive Decision Support

Key Trends in IndustryKey Trends in IndustryKey Trends in IndustryKey Trends in Industry Meet plant OUTPUT requirements

– Eliminate unplanned failures

Control COSTS– ‘Smart’ skill set utilization – O&M COST

• Annual Maintenance Cost

– Optimize work planning – O&M COST• Analyze MTBF / MTBM

• % Unplanned Maintenance

• Work Order Compliance

– Control outage times• Utilize CMMS / Maint. Planning

Program PerformanceProgram PerformanceProgram PerformanceProgram Performance

1988 2001 Ideal

Reactive 55% 55% 10%

Preventive 30% 31% 25-35%

Predictive 10% 12% 45-55%

Proactive 5% 2% BalanceReliability Magazine’s 2002 report

Over 11 years, plants are still REACTIVE.

World Class organizations focus on PREDICTIVE

Cost Statistics of the HPI SegmentsCost Statistics of the HPI SegmentsCost Statistics of the HPI SegmentsCost Statistics of the HPI Segments Skill Sets

– 75% or operations retiring in the next 15 years

• ‘Gray matter is leaving the plant!’

Costs– 20-30% of costs are related to maintenance

Mechanical Reliability– 3-7% Capacity Impact in loss/slowdown in production of keykey

process equipmentprocess equipment due to unplanned down

• Largest is due to mechanical equipment (40%)

– Predictive Maintenance program shown to impact reductions to unplanned mechanical shutdowns by ~30%

* HPI = Hydrocarbon Process Industries* HPI = Hydrocarbon Process Industries

Operational Challenges of TodayOperational Challenges of TodayOperational Challenges of TodayOperational Challenges of Today ‘Our target is ZERO unplanned downtime!’

– Maximize Equipment Availability & Reliability• Plan all maintenance - HOW?

‘We are trying to be competitive today with a plant that is typically more than 40 years old - and so are our competitors.’– Extend Machinery Life & Rebuilds

‘We are running our equipment beyond its design capacity to handle the variety of materials that we must process’– Running equipment beyond rated capacity

• Increased Throughput, but without RISK?

Answer These Tough Questions...Answer These Tough Questions...Answer These Tough Questions...Answer These Tough Questions... What maintenance does the machine need during the next planned

shutdown?– Are the spare parts in my inventory?

– Is my spares inventory too large? Can the equipment run beyond the next scheduled outage? Do I know when cavitation is occurring?

– Fact: 40-60% of machine problems related to lack of feedback to operators*

• Automation systems provide feedback (i.e., CavitationCavitation) back to Operator

* Ron Moore book

Answer These Tough Questions...Answer These Tough Questions...Answer These Tough Questions...Answer These Tough Questions... Do you know the # of failures ranked by equipment typeequipment type?

– Rotating Equipment can be segmented into…• Pumps / Fans / Compressors

• Pumps can be segmented into…– Centrifugal / Recip / Rotary / special effect

What are your most problematic machines?– Are they the bottlenecks in your production facility?

• These machines = downtime cost for entire plant.– AutomatedAutomated monitoring strategy would be ideal for these cases

Answer These Tough Questions...Answer These Tough Questions...Answer These Tough Questions...Answer These Tough Questions... What are your Key Performance Indicators (KPI)?

– # failures, MTBF/MTBM

– Cost of Repairs, Avg. Repair Cost,

– Maintenance costs by Equipment Group

– Quantified Lost Production Opportunity (LPO)

– Ex.: ExxonMobil reduced maintenance costs 20% corporate-wide by considering these categorical cost concepts

Answer These Tough Questions...Answer These Tough Questions...Answer These Tough Questions...Answer These Tough Questions... Have you identified your most critical equipment?

– One facility has identified that…• ~ 6 machines can bring them to 0 output MOST MOST

CRITICALCRITICAL

• ~ 30 machines can reduce output to 40-60% ESSENTIALESSENTIAL

• Point: Some output is better than no output!– If production is $1M / day, then 50% output loss = $500K / day

» Likely comes from O&M Budget

– Ex.: TN Eastman has 27,000 pieces of equipment• 3% (or ~750) need online-predictive & protection (AMI 1)

• 26% (~7000) need online and walk-around (AMI 2 or 3)

• What percentage would your operations group tell you?

* AMI = Asset Management Index (1-5, 1 is most critical)* AMI = Asset Management Index (1-5, 1 is most critical)

Conclusions…Conclusions…Conclusions…Conclusions… The market is forcing major industrial facilities to adopt

new methods for the sake of profitability– Equipment is getting old…Running beyond design speeds…

Planning is everything– But we don’t have unlimited man-power – industry is challenged!

Trained skill sets are starting to retiring– How do you capture this knowledge?

Do I have MTBF statistics?– CMMS is becoming important tool for O&M strategies

Identify the machines that reduce greatest percentage of output reduction– These are most critical! Automation is easily justifiable.

AgendaAgendaAgendaAgenda Industry Trends & Challenges Machinery Health Strategy Automating Decision Support Key Points

Machinery Health StrategyMachinery Health StrategyMachinery Health StrategyMachinery Health Strategy

BusinessObjective

Identification

PlantAssessment

andBenchmarking

FailureDefensePlanning

PerformanceQuantification

DESIGN

TechnologyDeployment

ExpertiseOptimization

WorkProcess

Optimization

IMPLEMENTATION

PerformanceMeasurementand Analysis

ImprovementPlanning

REVIEW

ContinuousImprovement

Asset OptimizationAsset OptimizationAsset OptimizationAsset Optimization Technology

– To provide decision support

Expertise– Qualified personnel with

current knowledge

Work Processes – To focus resources on

priorities

AgendaAgendaAgendaAgenda Industry Trends & Challenges Machinery Health Strategy Automating Decision Support Key Points

Detect Detailed Machinery Detect Detailed Machinery ProblemsProblems– Unbalance, Misalignment, Unbalance, Misalignment,

Looseness, Shaft Cracks, Oil Whirl, Looseness, Shaft Cracks, Oil Whirl, Phase, Rubs, Gear and Bearing Phase, Rubs, Gear and Bearing ProblemsProblems

Automated Monitoring ConceptsAutomated Monitoring ConceptsAutomated Monitoring ConceptsAutomated Monitoring Concepts

LoosenessProblem!

Signal Processing Flow

FFT

Waveform

Spectrum

Transducer

Am

plit

ud

eA

mp

litu

de

Time

FrequencyData Collector/Analyzer

Rotation

Heavy Spot

1 revolution

Time

Amplitude

0

+

-

Time Waveform

3600 rpm = 3600 cycles per minute

60 Hz = 60 cycles per second

1 order = one times turning speed

360 degrees

1000 rpm 1 revolution

Time

Amplitude

0

+

-

Time Waveform

4 blades = vibration occurs 4 times per revolution

4 x 1000 rpm = vibration occurs at 4000 cycles per minute

= 4000 cpm

12 toothgear

1000 rpm1 revolution

Time

Amplitude

0

+

-

Time Waveform

12 teeth are meshing every revolution of the gear

12 x 1000 rpm = vibration occurs at 12,000 cycles per minute

= 2,000 cpm = 200 Hz

Time0

+

-

Time0

+

Time0+

-

-

Time0

-

+

Time Waveform contains all the different frequencies mixed together

Complex Time Waveform

Time Waveform contains all the different frequencies mixed together

Complex Time Waveform

We are now entering the Frequency Domain

•FFT - Fast Fourier Transform•Separates individual frequencies•Detects how much vibration at each frequency

TIME WAVEFORM

AMPLITUDE VS TIME

Am

plitu

de

Frequency

Am

plit

ude

Time

Am

plitu

de

Time

Amplitude

Time

Frequency

Time0

-

Time0

+

Time0+

-

-

Frequency

Frequency

Frequency

1x

4x

12x

Predefined Spectrum Analysis BandsPredefined Spectrum Analysis Bands

20000

0.3

0.6

0.9

1.2

1.5

1.81xRPM - BALANCE

2xRPM - ALIGNMENT

3-5xRPM - LOOSENESS

5000 10000 15000

Frequency Hz

5-25xRPM 25-65xRPM

ANTI-FRICTION BEARINGS & GEARMESH

Bearing Fault Frequencies Function of the Geometry of the Bearing

Outer Race(BPFO)

Inner Race(BPFI)

Ball Spin(BSF)

Cage (FTF)

ROLLER BEARING EXAMPLE

Frequency Band Alarming and TrendingFrequency Band Alarming and Trending

Alarm

Trend ofBalance

Trend of Bearings

Alarm

Am

pli

tud

e

Sub-Harmonic 1X 2X Bearing Bearing Gears Bearing

1x 2x 25-60 x

.5in/sec

.1in/sec

Time(Days)

Time(Days)

WarningWarning

Detect Detailed Machinery Detect Detailed Machinery ProblemsProblems– Unbalance, Misalignment, Unbalance, Misalignment,

Looseness, Shaft Cracks, Oil Whirl, Looseness, Shaft Cracks, Oil Whirl, Phase, Rubs, Gear and Bearing Phase, Rubs, Gear and Bearing ProblemsProblems

Pass Information to DCS Plant Pass Information to DCS Plant Information Systems via OPCInformation Systems via OPC– Use existing plant LAN Ethernet Use existing plant LAN Ethernet

infrastructureinfrastructure

Automated Monitoring ConceptsAutomated Monitoring ConceptsAutomated Monitoring ConceptsAutomated Monitoring Concepts

LoosenessProblem!

Like Process Control for the Vibration WorldPLC

PLC

PLC

PLC

Control Room

Controllers/Servers

Network Hub,

Router, or Switch

Network Hub,

Router, or Switch

=

Customer Provided Windows 95/NT Workstation with CSI’s Online WATCH S/W loaded.

Maintenance Office

=

Customer Provided Windows 95/NT Workstation with CSI’s Online WATCH S/W loaded.

Reliability Engineering

General…to SpecificGeneral…to SpecificGeneral…to SpecificGeneral…to Specific

2301 Compressor - Asset Reliability System - CSI 4500 Series 2301 Compressor - Asset Reliability System - CSI 4500 Series Online RBMOnline RBMCONSULTANTCONSULTANTTMTM

Graphical Interfaces - OverallGraphical Interfaces - OverallGraphical Interfaces - OverallGraphical Interfaces - Overall

Graphical Interfaces - Specific FaultsGraphical Interfaces - Specific FaultsGraphical Interfaces - Specific FaultsGraphical Interfaces - Specific Faults

Overall Vibration 3.204 mils

Oil Whirl/Whip

Rubs

Unbalance

1x Peak

1x Phase

Misalignment

2x Peak

Monitored Fault Value

0.506 mils0.112 mils1.886 mils0.231 mils72 degrees0.107 mils1.886 mils

2x Phase (cracked shaft)

35 degree

Looseness

Non-Rotational

0.231 mils0.501 mils

Detect Detailed Machinery ProblemsDetect Detailed Machinery Problems– Unbalance, Misalignment, Looseness, Shaft Unbalance, Misalignment, Looseness, Shaft

Cracks, Oil Whirl, Phase, Rubs, Gear and Cracks, Oil Whirl, Phase, Rubs, Gear and Bearing ProblemsBearing Problems

Pass Information to DCS Plant Pass Information to DCS Plant Information Systems via OPCInformation Systems via OPC– Use existing plant LAN Ethernet Use existing plant LAN Ethernet

infrastructureinfrastructure

Confirm mechanical conditions will reach Confirm mechanical conditions will reach planned shutdown, i.e., planned shutdown, i.e., plant capacity plant capacity targettarget– Fix what is ‘Fix what is ‘broke’ before failurebroke’ before failure

Automated Monitoring ConceptsAutomated Monitoring ConceptsAutomated Monitoring ConceptsAutomated Monitoring Concepts

LoosenessProblem!

Outa

geFailure

Automation Technology – Best PracticesAutomation Technology – Best PracticesAutomation Technology – Best PracticesAutomation Technology – Best Practices Data-to-Information

– Assess condition/faults of machine in field• Report results – not just data

Accuracy of automated analysis– Combine analysis with machine operating condition

• Addresses false alarming

Report-upon-exception– Keep skilled analysts focused on problems

• Addresses the ‘data generator’ issue

Report-upon-Exception – not just dataReport-upon-Exception – not just dataReport-upon-Exception – not just dataReport-upon-Exception – not just data

- - - - - - - - HI - - - - - - - - - - - - - - URGENT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - HI - - - - - - - - - - - - - - URGENT - - - - - - - - - - - - - - - - - - - - - - - - - - - -

- - - - - - - HI HI - - - - - - - - - - - - - CRITICAL - - - - - - - - - - - - - - - - - - - - - - - - - - -- - - - - - - HI HI - - - - - - - - - - - - - CRITICAL - - - - - - - - - - - - - - - - - - - - - - - - - - -

URGENCYURGENCYCriticalCriticalUrgentUrgentNotifyNotifyNormalNormal

DEADBANDDEADBAND

RATE-OF-CHANGE (ROC)

Amplitude Report Amplitude Report ((ABSOLUTE EPLISONABSOLUTE EPLISON))

AM

PLI

TU

DE

AM

PLI

TU

DE

TIME HISTORYTIME HISTORY

DEADBANDDEADBAND

ALARM TYPESALARM TYPESFaultFault HI HIHI HICautionCaution HIHICautionCaution LOLOFaultFault LO LOLO LORateRate ROCROCAmplitudeAmplitude ABS EPSABS EPS

Deadband (hysterysis) - limits annoyance alarmsDeadband (hysterysis) - limits annoyance alarms

Time ReportTime Report

ACTIONSACTIONSRelay ActivateRelay ActivateRelay ActivateRelay ActivateRelay ActivateRelay Activate

Report on Exception

!Exception

OPERATE

RELAYS

System reports only when health CHANGES

11111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111O11111111111111111111111111111111111111111111111111111O111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111O1111111111111111111111111111111111111111111111111111111111111111O111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111

Benefits of Reporting only ExceptionsBenefits of Reporting only ExceptionsBenefits of Reporting only ExceptionsBenefits of Reporting only Exceptions

Too Much Data!Automation should handle data rejection soReliability Group only has to handle EXCEPTIONS

Logic helps to ID canned observations versusreporting numbers

Allows valuable human experience to be applied to analyzing problems

Result is - Eliminate repetitive work- Easy for end user- Efficient analysis only on problems- Optimize labor effort

AgendaAgendaAgendaAgenda Industry Trends & Challenges Machinery Health Strategy Automating Decision Support Key Points

HQ

Process Plant

AOS Server

Subsidiary

EmersonServiceProfessional

Submit Data

Access to Reports via Internet Link

KEY:

ReliabilityEngineer

Process Plant

Using Web Technologies to EnableUsing Web Technologies to EnableRemote Monitoring & AnalysisRemote Monitoring & AnalysisUsing Web Technologies to EnableUsing Web Technologies to EnableRemote Monitoring & AnalysisRemote Monitoring & Analysis Provides customers with cost-effective access to

information and expertise not previously available in their own plants

Asset Management IntegrationAsset Management IntegrationAsset Management IntegrationAsset Management Integration

Motors, pumps, fans, boilers, turbinesMotors, pumps, fans, boilers, turbinesmotor control centers, transformersmotor control centers, transformers

Assets

Device

Periodic MonitoringPeriodic Monitoring

I & C monitoring, measurement, and I & C monitoring, measurement, and regulationregulation

Control Bus (FieldBus, HART, Control Bus (FieldBus, HART, ProfiBus), Ethernet LAN, modemProfiBus), Ethernet LAN, modemConnectivity

Ethernet LANEthernet LAN

World Wide WebWorld Wide Web

Control and Application

Efficiency Efficiency MonitoringMonitoring

Device Device ManagementManagement

CMMSCMMSProcessProcess Decision Decision SupportSupport

OperationOperation

Process ControlProcess Control(DeltaV)(DeltaV)

Asset ManagementAsset ManagementOptimizationOptimization

GRA

Equipment Equipment DiagnosticDiagnostic

Condition Condition MonitoringMonitoring

EnterpriseEthernet WANEthernet WAN

Asset Asset Optimization Optimization

InterfaceInterface

AMS

AO Web Services

AMSweb

RBMware

AO Web Services

RBMweb

e-fficiency

e-fficiency AO Web Services

Emerson Asset Optimization ArchitectureEmerson Asset Optimization Architecture phase1phase1 Emerson Asset Optimization ArchitectureEmerson Asset Optimization Architecture phase1phase1

Data Collector

Asset Optimization Server

AOweb

Using Advances in Web TechnologyUsing Advances in Web TechnologyUsing Advances in Web TechnologyUsing Advances in Web Technology e-fficiency AMSweb Asset Optimization

web server

Link Relevant InformationLink Relevant InformationLink Relevant InformationLink Relevant InformationEmbed links to other sources of information

Key PointsKey PointsKey PointsKey Points

Automation & Decision Support Tools help the

plant meet OUTPUT & COST targets by…

– 1. Optimize Reliability Group’s Time / Effort

– 2. Capture Plant Knowledge

– 3. Reduce O&M Costs by Managing Reliability