Online Condition Monitoring

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 [email protected]
CONDITION MONITORING
Online Vibration Analysis
WWW.LUDECA.COM 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,
© 2012 LUDECA, INC. All rights reserved WWW.LUDECA.COM 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
© 2012 LUDECA, INC. All rights reserved WWW.LUDECA.COM CONDITION MONITORING
Lets focus on the type of equipment located in hospitals:
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Cooling Towers
Exhaust Fans
Ventilators
Motors
Pumps ( chill water pumps, condenser pumps)
Air Handlers
Chillers
Compressors
© 2012 LUDECA, INC. All rights reserved WWW.LUDECA.COM INTERVAL BASED VS. CONDITION BASED MAINTENANCE
Time based Maintenance
  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.
Vibra1on   The machines are stopped even there is no
reason to do so.
time
Stop 1
Stop 2
Stop 3
Stop 4
Stop 5
  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
  In this example there is one planned short
machine stop based on machine condition
Vibra1on Example: exchange of a coupling or for lubricating
the bearings inside a gearbox
Alarm
Warning
Pre-Warning
 The second intervention is a scheduled machine
stop based on machine condition
time
© 2012 LUDECA, INC. All rights reserved 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.
WWW.LUDECA.COM ASSETS AND CRITICALITY
What are the most critical assets for all hospitals?
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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?
© 2012 LUDECA, INC. All rights reserved WWW.LUDECA.COM 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?
$$$$$$$$
© 2012 LUDECA, INC. All rights reserved WWW.LUDECA.COM 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.
© 2012 LUDECA, INC. All rights reserved WWW.LUDECA.COM HEALTH AND SAFETY
© 2012 LUDECA, INC. All rights reserved WWW.LUDECA.COM 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
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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
© 2012 LUDECA, INC. All rights reserved WWW.LUDECA.COM 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)
© 2012 LUDECA, INC. All rights reserved WWW.LUDECA.COM CMS OVERVIEW
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SYSTEM OVERVIEW
© 2012 LUDECA, INC. All rights reserved WWW.LUDECA.COM B WC D
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CMS OVERVIEW
Overall Vibration Trends – Vibration & Bearing Monitoring
© 2012 LUDECA, INC. All rights reserved WWW.LUDECA.COM CMS OVERVIEW
Overall Vibration Trends – Vibration & Bearing Monitoring
© 2012 LUDECA, INC. All rights reserved WWW.LUDECA.COM CMS OVERVIEW
© 2012 LUDECA, INC. All rights reserved WWW.LUDECA.COM CMS OVERVIEW
Smart Monitoring of Machine Faults: Unbalance Misalignment Electrical Problems Bearings © 2012 LUDECA, INC. All rights reserved WWW.LUDECA.COM CMS – PLC_SCADA INTERFACE
© 2012 LUDECA, INC. All rights reserved WWW.LUDECA.COM CMS – PLC _ SCADA INTERFACE
© 2012 LUDECA, INC. All rights reserved WWW.LUDECA.COM INTERFACE _ADDITIONAL
© 2012 LUDECA, INC. All rights reserved WWW.LUDECA.COM © 2012 LUDECA, INC. All rights reserved WWW.LUDECA.COM COOLING TOWERS
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COOLING TOWER EXAMPLES
Common Problems with cooling tower applications:
Motor :
bearing defects / misalignment / electrical fault frequencies
Gearbox: misalignment / gear mesh frequencies / bearings
Fan:
unbalance
© 2012 LUDECA, INC. All rights reserved WWW.LUDECA.COM 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. © 2012 LUDECA, INC. All rights reserved WWW.LUDECA.COM 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. © 2012 LUDECA, INC. All rights reserved WWW.LUDECA.COM CMS OVERVIEW
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ADDITIONAL METHODS OF COLLECTING DATA
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COOLING TOWER EXAMPLE
© 2012 LUDECA, INC. All rights reserved WWW.LUDECA.COM COOLING TOWER EXAMPLE
© 2012 LUDECA, INC. All rights reserved WWW.LUDECA.COM CMS
ONLINE SYSTEMS HELP DETECT MACHINERY FAULT PROBLEMS
Example: ALIGNMENT
© 2012 LUDECA, INC. All rights reserved WWW.LUDECA.COM MEASUREMENT LOCATIONS
ONLINE CMS – CW Feed Pump
© 2012 LUDECA, INC. All rights reserved WWW.LUDECA.COM 33 OVERALL VIBRATION VALUES
Position
Velocity (in/sec)
Non Drive End - V
0.25
Non Drive End - H
0.31
Non Drive End - A
N/A
Drive End - V
0.27
Drive End - H
0.10
Drive End - A
0.28
© 2012 LUDECA, INC. All rights reserved HIGH RADIAL HIGH AXIAL WWW.LUDECA.COM 34 OVERALL VIBRATION VALUES
HIGH RADIAL HIGH AXIAL © 2012 LUDECA, INC. All rights reserved 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
Drive End - A
0.32
WWW.LUDECA.COM 35 WHAT IS A SPECTRUM (FFT)?
• View Frequency verse amplitude • Helps determine problems associates with different frequencies • Help answer: “What is causing the high vibra1on?” © 2012 LUDECA, INC. All rights reserved 36 WWW.LUDECA.COM MISALIGNMENT
Misalignment indicated by 1X, 2X & 3X Running Speed
© 2012 LUDECA, INC. All rights reserved WWW.LUDECA.COM 37 MISALIGNMENT
Misalignment indicated by 1X, 2X & 3X Running Speed
Note: Only available in OMNITREND® Software
© 2012 LUDECA, INC. All rights reserved WWW.LUDECA.COM 38 ALIGNMENT REDUCES VIBRATION LEVELS
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VIBRATION ANALYSIS…….
VibraNon analysis catches failure ALIGNMENT tools reduce vibraNon levels © 2012 LUDECA, INC. All rights reserved WWW.LUDECA.COM 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 Email Increase availability and extend MTBR
© 2012 LUDECA, INC. All rights reserved WWW.LUDECA.COM THANK YOU
Alex Nino
LUDECA, INC.
1425 N.W. 88TH Avenue
Doral, FL 33172
(305) 591-8935
www.ludeca.com
WWW.LUDECA.COM