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Plant Condition Monitoring PDF

A machinery management system provides condition monitoring of plant assets through four levels: visual inspection, sensor-assisted inspection, indicator analysis, and computer-aided data acquisition. It aims to optimize machinery operation and process efficiency by acquiring machine condition data, protecting machinery, analyzing condition data, sharing information, and assessing machinery health. The goals are improved profitability through increased efficiency, reduced downtime, and lower maintenance costs. Key components include measuring vibration, alignment, lubricant analysis, and protecting machines by directly triggering emergency shutdowns based on multiple sensor inputs.

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Jahidul Islam
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394 views61 pages

Plant Condition Monitoring PDF

A machinery management system provides condition monitoring of plant assets through four levels: visual inspection, sensor-assisted inspection, indicator analysis, and computer-aided data acquisition. It aims to optimize machinery operation and process efficiency by acquiring machine condition data, protecting machinery, analyzing condition data, sharing information, and assessing machinery health. The goals are improved profitability through increased efficiency, reduced downtime, and lower maintenance costs. Key components include measuring vibration, alignment, lubricant analysis, and protecting machines by directly triggering emergency shutdowns based on multiple sensor inputs.

Uploaded by

Jahidul Islam
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Plant Condition Monitoring

Condition Monitoring of Plant


Assets (Machinery)

A method to manage
machinery assets, so their
operation can be optimized
along with the process

Condition monitoring
Condition monitoring systems
is capable of providing the
exact information required to
the right people at the right
time for uninterrupted and
trouble free operation of the
machinery

Levels of Condition monitoring

Level
Level
Level
Level

1
2
3
4

Visual inspection
Sensor-assisted inspection
Indicator analysis
Computer aided data
acquisition system

Level 1 Visual inspection

Seeing
Hearing
Touching
Smelling

Level 2 Sensor-assisted inspection


Data recording with the assistance
of portable instruments

Level 3 Indicator analysis

The condition of lubricant,


presence wear debris in gear box
oil or engine oil should be
analyzed in a sophisticated test
laboratory

Level 4 Computer aided data


acquisition system
Condition monitoring involves
Computer aided data
acquisition system

Condition monitoring
Vibration Analysis
Lubricat (oil) analysis
Alignment
Mass balancing
Ultrasound analysis

Benefits from Condition Monitoring


& Diagnostic System

Optimized plant efficiency,


reliability and availability
Monitoring process under
normal and critical
conditions

Reduce outage time


resulting from operational
errors
Reduced maintenance
cost

Machinery Management System


can be broken into five sections

Machinery Measurements
Machinery Protection
Machinery Condition Data Acquisition
Machinery information System
Interface to share the information with
anyone on the Plant Network

Organizing the Program


List critical machines to be
included in the program.
Establish the acceptable levels of
machinery vibration.
Determine the normal vibration
characteristics for each machine
(vibration signature base line)

Organizing the Program


Select, identify periodic check
points for all machines under
this programme
Select the interval for periodic
vibration checks
Design a simple data recording
& storing system

Organizing the Program


Develop an adequate data
analysis procedure
Train additional personnel to
carry out the program

Machine Category
Critical Machinery
Essential Machinery
General Purpose Machinery

Critical Machinery
The group of rotating
equipment which is absolutely
necessary to a major part of the
plant process.
Machines in this category are
usually unspared and should
be monitored continuously.

When critical machinery is


not operating, that part of
the process is not operating,
the overall plant is not
operating.

Essential Machinery
The group of rotating
equipment which is critical to a
part of the plant process.
Machines in this category can
be spared or unspared and
should be monitored
continuously.

When essential machinery is


not operating, the overall
plant is not operating to full
capacity.

General Purpose Machinery


The group of rotating
machinery which is not critical
to any part of the overall plant
process. Many of these
machines have tandem or
spared installations.

Many of these machines are not


monitored or are periodically
monitored (monthly or weekly) by a
technician with a portable
monitoring device.

Methodology for machine


malfunction diagnosis
Know the basic mechanical, fluidic,
thermal, and electrical (as applicable)
characteristics of the machine (Critical
speeds, Mode shape, Amplification factor)
Know the types of malfunction
mechanisms and their corresponding
symptoms that the machine is likely to
incur (unbalance , Flid induced Instability,
Thermal warping, etc.)

Methodology for machine


malfunction diagnosis
Monitor the key parameters that will indicate
a change in condition of the machine
(eccentricity, thrust position etc.)
Reduce diagnosis data into interpretable
formats and compare the results with
analytical predictions (Half spectrum, Full
spectrum, Orbit & Shaft centerline plots, etc.)

Methodology for machine


malfunction diagnosis
Present data on the machine condition in
as solid engineering form as possible
Take prompt action based on the machine
diagnosis

German Standard VDI 205

Lubrication analysis

Properties of
Lubricating oil
Viscosity
Colour
Specific gravity
Viscosity Index
Acid number

Pour point
Flash point
Aging
Foaming
De-emulsification

The four fundamental laws


of lubrication
Select the Correct lubricant
Keep it Clean
Keep it Dry
Keep it Cool

Lubrication analysis
How is oil cleanliness quantified?
How clean is new oil?
How clean does your oil need to
be?
What improvements in machine life
can you expect from cleaning up
your oil?

Machinery Management System

A method to manage
rotating machinery assets,
so their operation can be
optimized along with the
process

A machinery management
system provides data or
information that is
interpreted and applied by
people to correctly operate,
maintain, improve the
operation and assess the
condition of machinery.

Objective Of Machinery
Management System?

To improve profit margins


by increasing machine
efficiency, reducing or
eliminating unscheduled
down time and reducing
overall operation
maintenance cost

Machine Condition Data Acquisition

Machinery measurement

Machinery measurement

Radial vibration
Axial thrust position
Eccentricity
Mode Shape
Differential thermal expansion

Machinery Protection
Protection systems are used
to ensure personnel safety,
prevent or minimize
machine damage & limit
environmental impact

South africa

UFFL

Machinery Protection
The machine Protection
systems should be able to
monitor more than just overall
vibration amplitude

Machinery Protection
By monitoring more than
just overall vibration
amplitude, you can help
increase machine
availability & reduce
machine costs

Machinery Protection
The shutdown signals that
may come from the
monitoring system for a
protective action should not
go through the control
system

Machinery Protection
The relays associated with
the monitoring system
should provide the shutdown
signals or protective action
directly to the emergency
shutdown system

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