Online Condition Monitoring

Transcription

1 Online Condition Monitoring H.V.A.C. equipment is often hard to access, posing a problem maintenance crews and/or any portable data collection. Often considered expensive and difficult to get started it is quite easy and economical. This session will help you understand the possibilities of remote condition monitoring, easy diagnosis, and the ability to increase your uptime of your equipment. We will cover the various types of opportunities within hospitals and the type of communication readily available. Alex Nino is an application engineer with LUDECA, Inc. in Doral, FL. He has over 10 years experience in the fields of alignment, vibration analysis and balancing. Alex has a Bachelors of Science degree in Electrical and Computer Engineering from the University of Florida and holds an ISO Level 1 Vibration Analysis certification. Alex currently manages the LUDECAwind division of LUDECA, Inc. focusing on reliability and maintenance of wind turbines. He can be reached at Alex.Nino@ludeca.com

2 CONDITION MONITORING Online Vibration Analysis

3 ONLINE CONDITION MONITORING WHAT IS CONDITION MONITORING: Condition Monitoring is the process of monitoring a parameter of conditions in machinery, such that a significant change is indicative of a developing failure. It is a component of Preventive and Predictive Maintenance. The use of condition monitoring allows maintenance departments and facility engineers to make decisions and schedule work and other actions to be taken. The idea behind condition monitoring is to avoid the consequences of failure,

4 CONDITION MONITORING What type of parameters are used to reference Condition Monitoring? Example: - Vibration Analysis - Temperature - Oil Monitoring A deviation must occur between a set value and current running conditions for identifying machinery damage. Example of Failures: - Bearing - Gears - Fan / Unbalance - Misalignment

5 CONDITION MONITORING Lets focus on the type of equipment located in hospitals: - Cooling Towers - Exhaust Fans - Ventilators - Motors - Pumps ( chill water pumps, condenser pumps) - Air Handlers - Chillers - Compressors

6 INTERVAL BASED VS. CONDITION BASED MAINTENANCE Time based Maintenance Vibra1on As there is no information or measurement data about the condition of the machine, maintenance intervals are set every certain operating hours or elapsed time. The machines are stopped even there is no reason to do so. Stop 1 Stop 2 Stop 3 Stop 4 Stop 5 time In addition, parts that may last longer are changed before their component lifetime has been reached. A greater number of spare parts are required on stock. Bottom line: interval based maintenance is not a very good choice Predictive Maintenance Vibra1on Alarm Warning Pre-Warning time In this example there is one planned short machine stop based on machine condition Example: exchange of a coupling or for lubricating the bearings inside a gearbox The second intervention is a scheduled machine stop based on machine condition Example: correction of unbalance with a field balancing instrument, correction of misalignment with a laser alignment tool, exchanging certain parts e.g. bearings or other components.

7 ASSETS AND CRITICALITY What are the most critical assets for all hospitals? - Are they cooling towers? - Are they air handlers? - Are they blowers? - Are they pumps? - Is the air handler on top the surgical room driving a surgeon crazy? - Is the there enough air flowing through certain rooms which contain either biological test samples or current medical test? - Are certain rooms maintaining the appropriate room temperature? Does all of this sound familiar or somewhat familiar?

8 ASSETS AND CRITICALITY Can you afford to have one of those critical machines go down? Do you have redudancy inside your hospital facilities? Do you have enough maintenance staff to assist and repair these machines, if they fail Do you have enough spare parts in the warehouse? How much time can your machine be down? $$$$$$$$

9 HEALTH AND SAFETY If your hospital or facility are like many others, you are probably not performing condition based maintenance (CbM). Prior to beginning a good CbM program, health and safety of your employees should your first concern. Many rotating equipment inside a hospital are not easily accessible, hence, causing Some negativity among management and/or maintenance crews.

10 HEALTH AND SAFETY 2012 LUDECA, INC. All rights reserved

11 HEALTH AND SAFETY How can we check: Bearings? Sheaves? Misalignment? Vibration? The amount of force being pulled by the fan can cause any one to be sucked in. Should we monitor this equipment? Answer: Yes u 5ffT5 e d 11 A I, A, Ar o o

12 CONDITION MONITORING SYSTEMS (CMS) Online monitoring allows to customers with shortcomings in skills or available personnel to properly monitor your equipment efficiently and accurately. Online monitoring does not require fully trained skill personnel to use Having a CM Online system will allow you to properly surveillance your asset on a 24/7 cycle and properly alert users of the conditions of the machine. It provide smaller intervals between measurements: Online CMS perform measurements several times a day per measurement point (-> e.g. failures with a quick evolution of failure can be predicted effectively) Trends are registered continuously ensuring detection of any variation in machinery health

13 CONDITION MONITORING SYSTEMS (CMS) It is very difficult to collect data of irregular or temporarily increase of vibration Example: with offline you must be in the right place at the right time! Critical machines that are an element in production processes require online monitoring which allows highest reliability condition monitoring ideal for critical machines Less intervention of plant personal is required: (online CMS does the measurements and handles alarming, etc) Less time is invested in collecting measurement data Allows maintenance and reliability personnel to dedicate time to other important tasks Optimization of data to be supplied to Supervision systems like SCADA or Building Automation systems (ex. Johnson Control systems, Siemens, etc)

14 CMS OVERVIEW u 5ffT5 e d 11 A I, A, Ar o o

15 SYSTEM OVERVIEW

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17 CMS OVERVIEW Overall Vibration Trends Vibration & Bearing Monitoring

18 CMS OVERVIEW Overall Vibration Trends Vibration & Bearing Monitoring

19 CMS OVERVIEW

20 CMS OVERVIEW Smart Monitoring of Machine Faults: Unbalance Misalignment Electrical Problems Bearings

21 CMS PLC_SCADA INTERFACE

22 CMS PLC _ SCADA INTERFACE

23 INTERFACE _ADDITIONAL

24

25 COOLING TOWERS u 5ffT5 e d 11 A I, A, Ar o o

26 COOLING TOWER EXAMPLES Common Problems with cooling tower applications: Motor : bearing defects / misalignment / electrical fault frequencies Gearbox: misalignment / gear mesh frequencies / bearings Fan: unbalance

27 COOLING TOWERS How To Measure? They are NOT easy to access Accessing cooling tower gearboxes and fan bearings for vibranon analysis has always been a challenge for many predicnve maintenance programs. While the motor is o_en accessible, the gearbox and fans are usually located inside the cooling tower cell, making these components inaccessible while the fan is in operanon. Many companies are creanng a program to monitor the inaccessible machine components of cooling towers by permanently mounnng low- cost accelerometers and cables to the gearboxes and fans and connecnng them to a single, centrally located switch box for quick and convenient access.

28 TYPICAL DAMAGES IN COOLING TOWERS Failures Gearbox: the gearbox can be a source of excessive maintenance for several reasons. Located inside the cell, it is subjected to aerodynamic loading from the fan, misalignment of the gear to the motor and/or excessive loading on the gear teeth. Environmental factors can also contribute to gearbox degradanon. Chemicals added to the water to control the ph of the cooling tower water are typically causnc. Motor: Since the cooling tower motors are more readily accessible to the vibranon analyst, portable measurements (magnet- mounted accelerometers) are used to monitor their condinon. Motor unbalance, rotor bar defects, output sha_ alignment and bearing defects are typical faults detected. Fan: although infrequent, can be catastrophic. If undetected, the fan blades can detach and damage the cell and surrounding components.

29 CMS OVERVIEW u 5ffT5 e d 11 A I, A, Ar o o

30 ADDITIONAL METHODS OF COLLECTING DATA u 5ffT5 e d 11 A I, A, Ar o o

31 COOLING TOWER EXAMPLE

32 COOLING TOWER EXAMPLE

33 CMS ONLINE SYSTEMS HELP DETECT MACHINERY FAULT PROBLEMS Example: ALIGNMENT

34 MEASUREMENT LOCATIONS ONLINE CMS CW Feed Pump 33

35 OVERALL VIBRATION VALUES Position Velocity (in/sec) Non Drive End - V 0.25 Non Drive End - H 0.31 HIGH RADIAL Non Drive End - A N/A Drive End - V 0.27 Drive End - H 0.10 Drive End - A 0.28 HIGH AXIAL 34

36 OVERALL VIBRATION VALUES HIGH RADIAL Position Velocity (in/sec) Non Drive End - V 0.32 Non Drive End - H 0.21 Non Drive End - A Cavitation 18 db Drive End - V 0.23 Drive End - H 0.10 HIGH AXIAL Drive End - A

37 WHAT IS A SPECTRUM (FFT)? View Frequency verse amplitude Helps determine problems associates with different frequencies Help answer: What is causing the high vibra1on? 36

38 MISALIGNMENT Misalignment indicated by 1X, 2X & 3X Running Speed 37

39 MISALIGNMENT Misalignment indicated by 1X, 2X & 3X Running Speed Note: Only available in OMNITREND Software 38

40 ALIGNMENT REDUCES VIBRATION LEVELS u 5ffT5 e d 11 A I, A, Ar o o

41 VIBRATION ANALYSIS. VibraNon analysis catches failure ALIGNMENT tools reduce vibranon levels

42 OVERVIEW Reduce your opera1ng cost: Reduce replacement parts Avoid catastrophic failure Reduce the need for unscheduled downtown Control opera1on: IdenNfy damaging operanon condinons Spot component wear during operanon Data where you need it: ProtecNon data for building automanon system via Modbus or SCADA Analysis data for engineers via Internet or Increase availability and extend MTBR

43 THANK YOU Alex Nino LUDECA, INC N.W. 88 TH Avenue Doral, FL (305)