Predictive Maintenance Predictive Maintenance Optimization Optimization --

Developing An Effective Machinery Developing An Effective Machinery Management ProgrammeManagement Programme

2

MechanicalMechanicalEquipmentEquipment

ProcessProcessEquipmentEquipment

Instruments Instruments & Valves& Valves

ElectricalElectricalEquipmentEquipment

Emerson’s Asset Optimization MissionEmersonEmerson’’s Asset Optimization s Asset Optimization MissionMission� Deliver World-Class Services and Innovative

Technologies to Increase the Availability and Performance of Production Assets for Improved Bottom Line Results (operational excellence).

3

Machinery Health ManagementMachinery Health ManagementMachinery Health Management

Balance technology, expertise, and work processesfor maximum availability at best cost.

MotorsMotors PumpsPumps TurbinesTurbinesGearboxesGearboxes

Increases Availability and Performance ofMechanical EquipmentIncreases Availability and Performance ofMechanical EquipmentMechanical Equipment

4

Vibration Vibration AnalysisAnalysisPortable & Portable & WirelessWireless

Laser Laser AlignmentAlignment

OnOn--Line Line Condition Condition MonitoringMonitoring

InfraredInfraredThermographyThermography

Motor Motor DiagnosticsDiagnostics

UltrasonicsUltrasonics

BalancingBalancing

ODBCODBC

MIMOSAMIMOSACMMSCMMS

RBMRBM viewview

TribologyTribology

5

Asset Optimization Services Mechanical EquipmentAsset Optimization Services Asset Optimization Services Mechanical EquipmentMechanical Equipment� Vibration analysis – portable, online, and wireless

– Motor analysis– Laser alignment and balancing

� Oil analysis– Trivector Laboratory: industrial lubrication problem detection and detailed

analysis– On-site Analysis Equipment

� Sonic and ultrasonic analysis � Infrared thermography

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� Vibration Analysis– Identification of misalignment, imbalance, bearing

defects, structural foundation issues and electrical related problems

� Tribology/Oil Analysis– Identification of wear particles, chemical changes and

contaminants; “clean, dry and fit for use”– May also be used as an acceptance determination for

the incoming oils from the Lubrication Supplier

TribologyTribology

7

� Ultrasonics/Sonics Survey– Air, steam trap, valve & vacuum leak detection– Bearing lubrication effectiveness

� Infrared Thermography Survey– Detection of proper electrical connections; switchgear– Detection of proper insulation from heat sources

� AMS Machinery Health Manager– Integration of multiple CM technologies

InfraredInfraredThermographyThermography

UltrasonicsUltrasonics

Vibration AnalysisVibration Analysis

Understanding How Machines FailUnderstanding How Machines Fail

ACCEPTANCESTANDARDS

COMMISSIONING

WEAR-OUTZONE

PR

OB

AB

ILIT

Y O

F F

AIL

UR

E

INFANTMORTALITY

ZONE

RANDOM FAILURE

OPERATING AGE

STARTUP FAILURE RANDOM / OPERATIONAL FAULTS WEAR OUT

PREDICTIVE MAINTENANCEPRECISION CORRECTIONS

PREVENTIVE MAINTENANCE

PREDICTIVE MAINTENANCE

ROOT CAUSE

10

Principle #1 of Vibration AnalysisPrinciple #1 of Vibration AnalysisPrinciple #1 of Vibration Analysis� Mechanical faults generate

unique vibration – Geometry of the machine

• diameter of the shaft, number of bearing elements, etc.

– Turning speed (e.g. RPM)

Mechanical Defects detected with vibration analysis

�Belt drive faults�Imbalance�Misalignment�Bent shaft�Looseness�Machine resonance

�Cavitation�Shaft Rub�Bearing Defects including:

ocage defectoouter race defectoinner race defectorolling element defect

�Gear defects�Electrical faults

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Time0

+

-

Time

Time

0

+

-

0

+

-

Vibration from Mechanical FaultsVibration from Mechanical FaultsVibration from Mechanical Faults

12

Understanding the Vibration SpectrumUnderstanding the Vibration SpectrumUnderstanding the Vibration Spectrum

Transducer

Overall Energy

FFT

Waveform

Spectrum

Am

plitudeA

mplitude

Time

Frequency

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FFT Signal ProcessingFFT Signal ProcessingFFT Signal Processing

Frequency

Am

plitu

de

Time

Am

plitu

de

Time

Am

plitu

de

14

A Typical FFT SpectrumA Typical FFT SpectrumA Typical FFT Spectrum

Specific peaks typically correlate to

Specific machine faults

Related to machine speed

Need Spectrum Analyzer for diagnostics, not just Overall vibration meter

15

Frequency Bands in addition to SpectrumFrequency Bands in addition to Frequency Bands in addition to SpectrumSpectrum

Divide spectrum in frequency bands based on the types of mechanical faults that might appear on the machine

1X

2X3X- 6X

BEARING BAND 1 BEARING BAND 2

9-30X RPM30-50X RPM

Imbalance

Misalignment

LoosenessBearing Band 1 Bearing Band 2

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Imbalance

Imbalance typically appears at the turning speed of the machine

Diagnose Nature of FaultDiagnose Nature of FaultDiagnose Nature of Fault

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Misalignment

Diagnose Nature of FaultDiagnose Nature of FaultDiagnose Nature of Fault

Misalignment typically shows up at either 1 or 2 x turning speed

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Looseness

Diagnose Nature of FaultDiagnose Nature of FaultDiagnose Nature of Fault

Looseness shows up as multiples of turning speed

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Diagnose Nature of FaultDiagnose Nature of FaultDiagnose Nature of Fault

Bearing wear shows up at specific peaks related to the geometry of the bearing

Bearing Wear

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Roller Bearing Vibration FaultsRoller Bearing Vibration FaultsRoller Bearing Vibration FaultsFour different bearing frequencies

Ball Spin Frequency(BSF)

Fundamental TrainFrequency(FTF)

Ball Pass FrequencyInner Race(BPFI)

Ball Pass Frequency Outer Race(BPFO)

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Outer Race Impacting

Inner Race Impacting

How Bearing Faults Generate VibrationHow Bearing Faults Generate How Bearing Faults Generate VibrationVibration

22

Motor Current AnalysisMotor Current AnalysisMotor Current Analysis� Easy to add to Vibration

program

� Rotor / Stator defects– Difficult to detect in Vibration

signature

– Use current analysis instead, but opening MCC is risky

– Use magnetic flux analysis for safety/convenience

23

Dynamic Structural DisplayDynamic Structural DisplayDynamic Structural Display

ODS & Modal Analysis

ODS = Operational Deflection Shape

24

ImplementationImplementationImplementation� Periodic basis using portable data collection

equipment� Continuous basis using a dedicated, permanently

installed monitoring system– high implementation cost in terms

• capital acquisition• disruption to production during installation

� Current trend toward ‘right-sizing’– forced to examine techniques to reduce or eliminate

manpower for data collection and analysis

ThermographyThermography

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What is infrared thermography?What is infrared thermography?What is infrared thermography?� A non-intrusive

technology that allows you to “see” your equipment’s health.

� Therm - a form of the Greek word for heat

� Graph - a writing or representation

� Thermography - a representation of heat

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How does infrared thermography work?How does infrared thermography How does infrared thermography work?work?� Thermography is a visual

representation of temperature.

� Infrared imagers detect heat given off a surface & convert it into electronic signals.

� Different temperatures correspond to different energy levels seen by different colors.

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Why use thermography?Why use thermography?Why use thermography?� Safe - Non-intrusive, non-

contact, and non-destructive

� Fast - Quick, easy data collection

� Real time analysis -transient data can be captured and analyzed

� Cost effective - new, low-cost imagers provide very quick ROI

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ApplicationsApplicationsApplications� Process

– Extrusion– Pipe insulation breakdown– Refractory breakdown– Fluid storage tank level– Food industry– Rolling kiln– Injection molding

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ApplicationsApplicationsApplications� Electrical Inspections

– Unbalanced loads,– Eddy current heating,– Improperly sized fittings, – Broken strands...

� Electrical equipment– Bad connections, breakers,

fuses– Overloaded conditions– Motor Control Center

components– Distribution lines– Cable trays/conduits

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ApplicationsApplicationsApplications� Mechanical inspections

– Bearings– Steam traps– Gears– Belts– Couplings– Motor insulation breakdown

32

ApplicationsApplicationsApplications

Leakage from a steam trap.

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Thermography benefitsThermography benefitsThermography benefits� Infrared inspection verifies machinery

temperature & locates potential electrical problems.

� Regular checkups assist in extending equipment life & delaying capital expenditures for equipment replacement.

� Management knows what problems exist, severity & specifics about the problem.

� Maintenance priorities set according to the problem severity level

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Problem?

IR Thermography shows the heat & the

problem

See The Heat, See The ProblemSee The Heat, See The ProblemSee The Heat, See The Problem

35

See The Heat, See The ProblemSee The Heat, See The ProblemSee The Heat, See The Problem

IR Thermography shows the heat & the

problemProblem?

“A picture is worth a thousand words. You can scan a room very quickly, and the infrared images are powerful and very easy to explain. Other technologies can take days to find

the problem, figure it out, and report to management.”

Senior Reliability Engineer

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Thermography ExampleThermography ExampleThermography Example

Explanation: The connection end of the incoming wiring for phase B to plant breaker 7 is warmer (+25C) than the other wiring for the same circuit. This indicates a poor connection or failing breaker. Recommendedactions based on delta T and voltage are to inspect and repair/replace BEFORE THE NEXT SCHEDULED OUTAGE (Within 3 Months).

Voltage Delta T(C) % Load Emissivity Reference T Background T480 25 100 0.85 160ºC 80ºF

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Thermography Example (Repaired)Thermography Example (Repaired)Thermography Example (Repaired)

Explanation: Following the repairs on 10/15, the hot connection has been fixed.

Sonics / Sonics / UltrasonicsUltrasonics

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What are Ultrasonic signals:Frequency Greater Than 20,000 HzWhat are Ultrasonic signals:What are Ultrasonic signals:Frequency Greater Than 20,000 HzFrequency Greater Than 20,000 Hz

‘A’ above middle ‘C’(440 Hz)

Steam trap(40,000 Hz)

Bearing defect (4,000 Hz periodic)

Sub-sonic Sonic Ultrasonic RangeUltrasonicUltrasonicUltrasonic

Under-lubricated bearing (30,000 Hz random)

20,000 Hz

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Sound Analysis Converts Inaudible Signals into Audible Ones Sound Analysis Converts Inaudible Sound Analysis Converts Inaudible Signals into Audible Ones Signals into Audible Ones

‘A’ above middle ‘C’(440 Hz)

Steam trap(40,000 Hz)

Bearing defect (4,000 Hz periodic)

Sub-sonic Sonic Ultrasonic RangeUltrasonicUltrasonicUltrasonic

Under-lubricated bearing (30,000 Hz random)

20,000 Hz

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Where Can You Apply Ultrasonics?Where Can You Apply Where Can You Apply UltrasonicsUltrasonics??

Transmission and

Distribution

Valves and

Piping

Pneumatic Controls

Bearings and

Gearboxes

Grease Lubrication

Control

Compressed Air

Steam Traps

Boiler Tubes

Motor/Pump

Control Valves

42

Typical Sound Analysis ToolsTypical Sound Analysis ToolsTypical Sound Analysis Tools

1) Airborne Probe

3) Magnet Mount Probe

2) Contact Probe

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� Primary Health Monitoring technique for:– Valves, steam traps, grease lubrication– Simple to use and understand– Very high return on investment

� Excellent ‘second opinion’ for:– Machinery Health Monitoring– Electrical equipment scanning

Why Use Sound Analysis?Why Use Sound Analysis?Why Use Sound Analysis?

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Application: Bearing DefectsApplication: Bearing DefectsApplication: Bearing Defects� Quick, easy test� Establish baseline� “Clicking” sound indicates

bearing damage� Trend sound level to track

developing faults

Bearing fault

(4 KHz)

Note: Trending only possible if using a calibrated ultrasonic device)

45

Application: Lubrication MonitoringApplication: Application: Lubrication MonitoringLubrication Monitoring

� 75% of bearing failure is lubrication related*� Damage occurs from both:

– Under-lubrication (Premature bearing failure, contamination, etc.)

and– Over-lubrication (Ball skidding, grease overflow, seal

damage, etc.)

*Source SKF bearings

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Application: Detecting Valve FailureApplication: Detecting Valve FailureApplication: Detecting Valve Failure� Failure Modes:

– Partially open or leaking– Sounds like rushing water

� Failure can result in:– Contamination– Loss of product– Damage to valves and

downstream equipmentDefective Valve

(40 KHz)

47

Application: Monitoring Control Valves Application: Monitoring Control Valves Application: Monitoring Control Valves � Contact measurement to

monitor flow rate� Airborne measurement to

monitor stem packing leaks

0

10

20

30

40

50

60

70

1 2 3 4 5 6

Control Valve #

Ave

rage

dB

Monitoring boiler spray valves

(average level)

Defective Valve

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Inlet Outlet

Application: Steam TrapsApplication: Steam TrapsApplication: Steam Traps� Sound created from turbulent

fluid flow and valve/float impact� Failed trap leads to significant

losses in steam systems� A blowing trap (1/4” orifice, 125

lb. steam) results in steam loss of $6,300 per year

Under lubricated bearing

(40 KHz)

Confirm fault with Thermography

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Air Leak

(40 KHz)

Application: Air LeaksApplication: Air LeaksApplication: Air Leaks� Primary loss of energy in

plants today.� Generates airborne

turbulence in the 40 kHz frequency range.

� A 1/8” air leak in a 100 psisystem results in a yearly loss of $2,100

� .005” orifice, 5 psi leak

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� Natural gas leak� Safety hazard� 83 dB amplitude,

approx. $28,000 per year

Application: Gas LeaksApplication: Gas LeaksApplication: Gas Leaks

Natural Gas Leak

(40 KHz)

51H

igh

Vol

tage

Hig

h V

olta

ge

Hig

h V

olta

ge

Electrical Corona and DischargeElectrical Corona and DischargeElectrical Corona and Discharge� Corona caused by:

– Insulation breakdown– Improper connections

� Generates high frequency waves

� “Buzzing” or “Crackling” sound� Confirm with IR Thermography

Corona from Faulty Connection

(>40 KHz)

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Application: Switchyard MonitoringApplication: Switchyard MonitoringApplication: Switchyard Monitoring� Sources of corona:

– Arcing in transmission lines

– Partial discharge in transformers

Electrical Corona

(>40 KHz)

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Application: Load Tap ChangersApplication: Load Tap ChangersApplication: Load Tap Changers

� Responsible for nearly half of all failures in Substations and Switchyards

� Scan for Nitrogen Leaks.

Corona on Load Tap Changer

(>40 KHz)

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Confirm Fault with IR ThermographyConfirm Fault with IR ThermographyConfirm Fault with IR Thermography� Inspection of load tap

changers requires multiple technologies – Scan with Ultrasonics– Confirm with IR and

test for dissolved gas

IR scan of Load Tap Changer

Documented Savings withDocumented Savings withSound MonitoringSound MonitoringAmerican Electric Power

John E. Amos Plant12 month ROI

Vibration Analysis $4,223,850Ultrasonic Monitoring $1,217,820Motor Testing $ 381,097Motor Current Analysis $ 344,429Infrared Analysis $ 343,650Lube Oil Analysis $ 74,039

Total $6,584,885

Lubricant AnalysisLubricant Analysis

What is What is TribologyTribology ??

� Tribology is the science and technology of interacting surfaces in relative motion.

� Includes much more than just OIL ANALYSIS

58

Vibration and Oil Analysis Used TogetherVibration and Oil Analysis Used Vibration and Oil Analysis Used TogetherTogether

� Complements vibration analysis – providing independent and advanced indications of

mechanical wear.

� Supplements vibration analysis– monitoring three root causes of failure:

• oil chemistry • oil contamination• component wear

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Root Causes of Surface DegradationRoot Causes of Surface DegradationRoot Causes of Surface Degradation

Lube Related Root Causes:

� Wrong oil� Mixed oil� Low oil� Degraded oil� Process contamination� Dilution� Water contamination� Dust contamination

Mechanical Root Causes:

� Imbalance� Misalignment� Improper assembly� Improper fit� Temperature extremes� Improper speed/load� Incompatible materials� Material defect� Seal defects

� Oil Deterioration - primarily due to oxidation which can produce acids which are detrimental to both componetry of machines and additives

What Causes A Lubricant To Fail?What Causes A Lubricant To Fail?What Causes A Lubricant To Fail?

� Additive Depletion - additives are lost or consumed during the performance of their functions

� Contamination - ingressed or generated contamination is the primary root cause of failure in many mechanical systems

Wear

Contamination Chemistry

Extreme

Bad

Marginal

Fair

Good

ABRAS WEAR - Abrasive Wear ExampleP3 - Mobil DTE hydraulic fluidSample Date: 21-FEB-93

Wear - Bad Contamination - Extreme Chemistry - Good

Bad seal leaking coolant into hydraulicsSaw abrasive wear particles on grid 100x

Check - Viscosity, Breather, Contamination, Shop Mic, MechanicalAction - Remove Contaminants (water?) Estimated total water content 2.5089%In Solution 1% +Emulsified 72% +Free 27% = 100%

Oil Analysis & Trivector DiagramOil Analysis & Trivector DiagramOil Analysis & Trivector DiagramOil analysis has three

dimensions:– Wear

• Ferrous• Nonferrous

– Contamination• Dust• Water• Process

– Chemistry• Oil• Additive

62

Oil analysis choicesOil analysis choicesOil analysis choices� On-site minilab

– No delay– Test incoming lubricants– Ownership and control– Find and fix contamination– Less expensive for >30

samples per month

� Off-site oil lab– No capital investment– Expertise– Extensive instrumentation– Less labor required– Less expensive for < 30

samples per month

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Oil LaboratoryOil LaboratoryOil Laboratory

� Wear Debris Analysis� Particle Count with Sizes� Ferrous Wear� Spectrometric Metals� Viscosity V40, V100, and VI� Neutralization Number� Water by KF� FT-IR

64

2.Iron and Water

3.Particle Count withSize Distribution

Oil MinilabOil Oil MinilabMinilab

1.Oil Chemistry and Viscosity

4.Wear Debris Analysis

65

Minilab Analysis ParametersMinilabMinilab Analysis ParametersAnalysis ParametersParameters What is measured? Significance

Wear ParametersFerrous Index Iron particles > 5 microns Recent abnormal wearLarge Ferrous Indication Iron particles >> 60 microns Abrasive wear indicationLarge Non-Ferrous Indication Other metals >> 60 microns Abrasive wear indicationAnalytical Wear DebrisAnalysis

Microscopic particleexamination

Wear severity and root cause

Contamination ParametersParticle Count ISO counts at 8 different sizes Dust, wear, & process

particlesContaminant Index Non-ferrous contaminants Corrosive fluid contaminationWater Contamination Water or other corrosive fluid Corrosive fluid contaminationFree Water Droplet indication Imiscible fluid droplets in oil Corrosion and poor lubrication

Chemistry ParametersChemical Index Deteriorated lubricant Lubricant no longer fit for useDielectric Permitivity Physical property of lubricant Wrong oil or degraded oilViscosity ISO viscosity grade Wrong oil or dilution with fuel

66

Types of ParticlesTypes of ParticlesTypes of Particles

Corrosion Sand Rust

Abrasion Fatigue Boundry

Reasonable Return on Investment: 500%+Reasonable Return on Investment: 500%+Reasonable Return on Investment: 500%+� First year savings:

$420,000– Deferred maint = $210,000– Less oil usage = $15,000– More credible = $20,000– Less reactive = $150,000– More accurate = $25,000

� First year cost: $80,000– Oil analysis = $20,000– Contam. control = $40,000– Improved lubrication

practices = $20,000

� ROI = (Savings/Cost)x100– (420/80)x100 = 525%

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Industrial oil analysis includes:

� Particle counts with ISO codes

� Particle size distribution

� Ferrous density measurement

� Wear debris analysis

���������!���

68

Mechanical Reliability (CSI)Mechanical Reliability (CSI)Mechanical Reliability (CSI)� Services and technology for improving the availability of mechanical

equipment through condition analysis– Vibration analysis – portable, online, and wireless– Oil analysis– Sonic and ultrasonic analysis– Infrared thermography– Motor analysis– Laser alignment and balancing

� RBMware, condition monitoring, analysis and reporting software� Reliability program benchmarking, program design, implementation

and optimization

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BusinessObjective

Identification

PlantAssessment

andBenchmarking

FailureDefensePlanning

PerformanceQuantification

DESIGN

TechnologyDeployment

ExpertiseOptimization

WorkProcesses

Optimization

IMPLEMENT& EXECUTE

PerformanceMeasurementand Analysis

ImprovementPlanning

REVIEW

CONTINUOUSIMPROVEMENT

Asset Optimization Program ModelAsset Optimization Program ModelAsset Optimization Program Model

70

71

PositioningPositioningPositioning

� Machinery Health Manager is the software platform for Machinery Health Management

– It Includes:

• Machinery health management TechnologiesTechnologies

• Data analysis tools & ExpertiseExpertise

•• Work ProcessWork Process for reporting program results

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Machinery Health ManagerMachinery Health ManagerMachinery Health Manager� Provides tools in assisting the RBM analyst to efficiently and accurately

determine the current health of equipment

• More confidence in diagnostic calls by the analyst and management (built-in intelligence & diagnostic options).

� Effectively communicate to appropriate personnel throughout the organization

• Communication through existing enterprise and information systems.• Reporting condition and recommending actions for prioritizing work• Tracking performance metrics for judging overall program success

� Initial implementation made easy.� PdM Novice user-friendly.� ROI realization is much quicker. � Integration of seven technologies

� Machinery Health Manager is the Platform for the entire RBM program.

73

Value Points/HighlightsValue Points/HighlightsValue Points/Highlights

� Integrated technologies for comprehensive multiple diagnostic detection

� Ease of use� Comprehensive setup, analysis, and

documentation tools� Built-in intelligence� Diagnostic Power� Equipment health tracking and reporting� Performance metrics documentation and

reporting� Flexible configuration capability(e.g. Single

User, LAN, WAN)

74

Software for Machinery Health ManagementSoftware for Software for Machinery Health ManagementMachinery Health Management� Data from diverse technologies

resides in one database structure – All personnel view the

complete history for each asset

– Technologies supported:• Vibration – portable and

online• Alignment & balancing• Motor Diagnostics• Infrared Thermography• Lubrication analysis &

Ultrasonics

Oil Analysis

Laser Alignment

& Balancing

Online Condition Monitoring

Ultrasonics

Portable

Vibration

Motor

MonitoringInfrared

Thermography

75

IntegrationIntegrationIntegration� Seven integrated technologies � Complete asset health condition

into a single database� All diagnosis and findings under

one asset in RBMview� Why not have all of the

symptoms of the equipment failure

� Know the whole story before making a recommendation

Wear

Contamination Chemistry

Extreme

Alarm

Alert

High Normal

Normal

Trivector

76

Ease of UseEase of UseEase of Use� Graphical User

Interface� Wizard Database setup� Don’t need to be vibration

expert to get started� Fast, comprehensive setup

means faster ROI� Automatic point, AP and AL

sets, Fault Frequencies, Diagrams, and Nspectr setup

77

Automated Database Set-upAutomated Database SetAutomated Database Set--upup

Assign measurement points, parameters, and alarm limits

Pre-definedcomponentsGraphic display of

configuration

Selection of component types

78

WAVEFORM DISPLAY 18-OCT-94 08:37:00 RMS = 4.38 PK(+) = 14.53 PK(-) = 11.78 CRESTF= 3.32

0 50 100 150 200 250 300 350

-15-12

-9-6-3

0369

1215

Time in mSecs

Acc

eler

atio

n in

G-s CF ALARM

CF ALARM

PK ALARM PK ALARM

MA#7 - GEARBOX DRIVE-SUCTION ROLLGBX-DSROLL-G3R G-BOX OUTPUT SHAFT - RADIAL

Label: Severe BPFO defect - need actionPriority: 4

ROUTE SPECTRUM 18-OCT-94 08:37:00 OVRALL= .6516 V-DG PK = .6892 LOAD = 100.0 FPM = 3518. RPM = 381.

0 400 800 1200 1600

0

0.1

0.2

0.3

0.4

0.5

0.6

Frequency in Hz

PK

Vel

ocit

y in

In/S

ec

Freq: Ordr: Spec:

79.29 12.50 .04412

>FAG 61896 G=BPFO

G G G G G G G G G G

BPFO harmonics show severe race defect

Multi-technology Analysis ToolsMultiMulti--technology Analysis Toolstechnology Analysis Tools� Technology and expertise… tools for

decision making– Vibration Analysis

• FFT, waveform, & phase analysis• Automated diagnostics expertise

– Lubrication Analysis• Trivector wear, chemistry, &

contamination analysis– Electric Motor Monitoring

• Automated rotor & stator diagnostics, using current & flux

– Infrared Thermography• Palette & plot annotation tools• Temp profile & histogram analysis

– Alignment & Balancing• Tolerance plots by the job

79

Diagnostic PowerDiagnostic PowerDiagnostic Power� Multiple plotting tools� Parameter band and narrow

band alarming� Fault Frequency analysis and

overlays� Variable speed diagnostics� Parameter Status Profile� Waveform Autocorrelation� PeakVue early impacting

analysis

80

MultipleAnalysisOptions

Fault frequenciesto identify specificnature of fault

MultiplePlotOptions

ReportLink

FastIndexing

Expert System Program Documentation

Diagnose Nature of FaultDiagnose Nature of FaultDiagnose Nature of Fault

81

Built-in IntelligenceBuiltBuilt--in Intelligencein Intelligence� RBMwizard sets up your

database for specific assets, not templates

� Thousands of built-in components(motors, bearings, pumps, gearboxes, etc) to generate helpful diagnostic fault frequencies

� Nspectr, rule based expert system finds problems and recommends corrective/ diagnostic actions

� Great for Novice and Expert

82

Automated Screening with Expert SystemAutomated Screening with Automated Screening with Expert SystemExpert System

MultipleDiagnoses

CalculatesProblemSeverity

CalculatesCertainty

Calculates Overall Severity

DiagnosisAcrossEntireMachineTrain

An alarm/screening report, and a first pass at analyzing machine condition

83

Reporting for Machinery Health ManagementReporting for Reporting for Machinery Health ManagementMachinery Health Management� Performance metrics

document program successes and opportunities

� ROI or cost avoidance documentation

� Identification of the 20% of assets giving 80% of the problems

84

Reporting for Machinery Health ManagementReporting for Reporting for Machinery Health ManagementMachinery Health Management� Condition tracking and

documentation� Reporting for technician and

management� Actionable information at

facility and machine level� Multi-technology asset

information repository

85

MechanicalMechanicalEquipmentEquipment

ProcessProcessEquipmentEquipment

Instruments Instruments & Valves& Valves

ElectricalElectricalEquipmentEquipment

Emerson’s Asset Optimization MissionEmersonEmerson’’s Asset Optimization s Asset Optimization MissionMission� Deliver World-Class Services and Innovative

Technologies to Increase the Availability and Performance of Production Assets for Improved Bottom Line Results (operational excellence).