ProSmart Predictive Condition Monitoring

Transcription

1 ProSmart Predictive Condition Monitoring Mark Brown ITT 2006 ITT Corporation

2 Time to Respond Page 2

3 How It Works Continuous machinery monitoring system designed for multi-plant predictive maintenance programs.

4 ProSmart System Architecture Data Monitor ProNet Communications Module Up to 50 Additional Machines Page 4

5 Communication DM CM 2.4 GHz / 200 mw Point Multipoint 1.6M Range (LOS) m Range (Plant) Hybrid MESH 1Q09 CM Internet Standard Ethernet M2MXML Cell / Satellite Modem DSL / LAN Wireless 256 Bit Encryption Internet - You Internet Explorer 128 Bit SSL Encryption Alarm groupings Alarm Notification Voice Portal Notification Page 5

6 Data Acquisition & Analysis Sensors Industrial Housing 304 SS Investment Cast NEMA 4x Class I Division 2 ABCD ITT ST-03 Vibration / Temp IMI pzt 3x Vibration Integrated Analysis 22 Channel D/A IMI pzt Vibration / Temp 5 Second sample cycles FFT Analysis (12C) Frequency Windowing Plug & Play I/O Tachometer V/T-30 Vibration 12 Axes Temperature 4 Pts Process Connections 4-20 ma Input (Qty 3) Digital Input (Qty 2) Form-C Relay Output (Qty 1) VDC Input ITT VT-02 Tachometer Process I/O Analog - Digital I/O Page 6

7 ProNet Dashboard Page 7

8 ProNet Machine Status Page 8

9 ProNet Trend Graphing Features Page 9

10 Spectral Analysis Fast Fourier Transform (FFT) Overall VIBRATION is comprised of multiple smaller vibrations due to condition such as IMBALANCE, MISALIGNMENT, VANE PASS, etc The overall vibration signal can be MATHMATICALLY dissected to reveal the individual contributing components. This mathematical analysis is called a Fast Fourier Transform. The resulting analysis can then be used to identify the source of vibration AND identify conditions that may ultimately cause machine failure. Severity (IPS) Page 10

11 ProSmart FFT Page 11

12 ProNet FFT Graphing Features Page 12

13 Band Alarms Frequency banding enables the monitoring of vibration characteristics KNOWN to be significant; e.g. Imbalance. ProSmart BAND ALARM function enables the trending of these characteristics over time. In the example to the right; vibration at 1X running speed is monitored over time. 1X running speed vibration is typically impeller (or rotor) imbalance. 00:00 06:00 12:00 18:00 00:00 Page 13

14 ProNet - Reports Page 14

15 ProSmart Applications PRIMARY Assets An unplanned failure of primary equipment can result in lost production and costly repairs Continuous monitoring with ProSmart informs you of equipment health and eliminates unexpected failures PROBLEM Solving The challenge of diagnosing problematic equipment is that they typically fail when you aren t there Sampling every 5 seconds, 24 hours a day, means ProSmart is there when you aren t Identifying the transient conditions that cause problems leads to real and permanent solutions REMOTE Locations Keeping track of remote equipment can consume valuable time and resources. ProSmart delivers key machinery health data directly to you; making the physically inaccessible, accessible. RELIABILITY Services Walk-around data collection methods take valuable time away from the real benefits of your vibration analysts; solving problems. It also misses critical transients and changes in the operating conditions of your equipment which can lead to faulty conclusions ProSmart automates the data collection process and links machinery health to operational conditions Page 15

16 Case Study: Primary Services Car Shredder 4000 HP, 10 pole motor Direct coupled to mill Roller bearings in motor and mill Operates 1 shift per day, 5 days per week Processes mixed metals (scrap, stamping press trim, automobiles, industrial metal waste, etc.) ProSmart Monitors Vibration Temperature Motor current Page 16

17 Alarm to Diagnosis From: From: To: To: Subject: Event notification: Mill DE Y Axis Subject: Event notification: Mill DE Y Axis (in/sec) Warning from Holland Shredder (f7) (in/sec) Warning from Holland Shredder (f7) Date: Thursday, May 15, :23 AM Date: Thursday, May 15, :23 AM Event: Mill DE Y Axis (in/sec) Warning Event: Mill DE Y Axis (in/sec) Warning Machine: Holland Shredder (f7) Machine: Holland Shredder (f7) Machine Data: Machine Data: Mill DE Y Axis (in/sec): inch/sec Mill DE Y Axis (in/sec): inch/sec High Warning Value: High Warning Value: Machine Time: 5/15/2008 6:22 AM Machine Time: 5/15/2008 6:22 AM Company: PADNOS Company: PADNOS Please do not reply to this message. Please do not reply to this message. Page 17

18 Case Study: Problem Solving 3600 Failures ITT Goulds Model 3600 (new) Repeated thrust bearing failures due to unknown causes. ProSmart monitors Vibration Bearing temperature Ambient temperature Cause Lack of ventilation in pump room resulting in high ambient temperature; thrust bearing housing unable to shed heat Page 18

19 Case Study: Remote Locations Energy Recovery MW Recovery process Located along LNG Pipeline Pieces of Rotating Equipment at each site Unmanned ProSmart Monitors Vibration Temperature Speed Value ProSmart links data back to main office in US and provides window to corporate offices overseas Source: Ormat Technologies Inc. Page 19

20 Potential Applications Anything that rotates Conveyor Pulleys (Head, Tail, Drive, Takeup) Conveyor Motors and Gearboxes Crushers Drag and Hoist Drum Bearings Drag and Hoist Gearboxes / Motors Swing Motors and Bearings Mobile Applications.Eg. Electric Wheels Etc.. Page 20

21 Thank You Page 21