nick lee - cm reporting and alarms

8/8/2019 Nick Lee - CM Reporting and Alarms

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CONDITION MONITORINGCONDITION MONITORING

Reporting and AlarmsReporting and Alarms

Loy Yang BLoy Yang B

Power StationPower Station


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Presentation OutlinePresentation Outline

! LYB Plant Basics

! Maintenance PhilosophyCM & Diagnostic Methods used at LYB

Overview of CM Program

! CM Reporting System

! Alarm setting for Vibration & Oil Analysis Data


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Plant Basics Loy Yang BPlant Basics Loy Yang B

! Nameplate capacity 2 x 500 MW gross Brown coal

units.! Long term capacity 508 MW gross/470 MW net)

! Unit 1 commissioned in 1993 and Unit 2

commissioned in 1996.

! High level of plant redundancy

! Wholly owned and operated by International Power

/Mitsui (IPM)


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Maintenance PhilosophyMaintenance Philosophy

! Overall Asset Management Plan for planning andmaintenance of plant systems (1yr, 5yr & 75yr)

! Plant that is monitored using CM methods haverelated maintenance activities based on conditionassessment and not time based. E.g. overhauls,

oil changes, bearing changes etc! Continuous improvement and Pro-Active

maintenance is enhanced through groups formedto tackle specific plant system problems.

RCA Program implemented

CMR Group

Plant Specific Groups (e.g. Mill Group, Boiler

Inspection Group etc)


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CMR GroupCMR Group

The CMR Group has tackled issues such as:

! Lubrication Management

! Lubrication system improvements

! RCA for Specific Problems

! Oil Purifiers for on-line oil cleaning and waterremoval

!

Training for CM Practitioners! CM equipment budgeting and procurement


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CM Proactive Approach1. Detection

2. Analysis3. Investigation (RCA)

4. Correction & Improvement (defect elimination)

5. Verification

6. Reporting & Documenting (History)


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Typical CM & Diagnostic MethodsTypical CM & Diagnostic Methods

! Vibration Analysis

! Lubrication/Oil Analysis

! Performance Testing

! Ultrasonic noise measurements

! Thermography

! Motor Current Analysis

! PHD Data Historian System

! RCA


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CM Data Management SystemsCM Data Management Systems

! Oil, Vibration (data collection), Current Analysisdata is stored using Rockwell Entek Odyssey

software.

! TG set On-Line Vibration Data stored in BentlyNevada DM2000.

! Pump Performance and Thermography data storedin other formats.

! PHD Data historian stores process information.

! Exceptions or Faults are recorded in a ConditionMonitoring Reporting (CMR) System, and includesWork Order numbers and faults detail.

! CMR System is an intranet based reporting system.


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CM Data Management SystemsCM Data Management Systems

Oil

Vibration

Electrical

TG On-

Line Data

PHD Data

Historian

Pump

Performance

Thermography

CM

Reporting

System


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Management (in-house)


Management (in-house)


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CM REPORTING SYSTEMCM REPORTING SYSTEM

Why was the CM Reporting Systemdeveloped?

! A CM Program needs to be managed.

! A CM Program is an Important part of assetmanagement and information needs to be readilyavailable.

! Management of the CM Program would be improved ifinformation was stored and presented in a betterformat.

!

Complexity of CM information needed to be reducedfor other stakeholders if it was to be considered. Production Engineering & Maintenance personnel Management

! MMS System information access and presentation wasnot adequate


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Problems with Previous CM Reporting

! Information on Plant Condition using various CM

methods was available to CM Practitioners only andwas not readily available to other Maintenance orProduction personnel.

!

Existing CM Software for Oil, Vibration and CurrentAnalysis, Performance data did not correlate thedata for a combined plant condition statement orassessment.

!Monthly Report was produced manually on worddocuments.

! Monitoring of Plant problems during early stages(prior to raising a Work Order) was done on a

dedicated white board.

CM REPORTING SYSTEM...CM REPORTING SYSTEM...


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CM REPORTING SYSTEM...CM REPORTING SYSTEM...

CMR System Overview

! Built on a Microsoft Access Database

Technical Specification written for IT Consultant.

! Provides a summary of plant condition from ONEreporting system.

! Correlates the different CM information to assist in

diagnosis of plant faults or problems.

! Provides more detailed information on plant if required.

CM Data & History

Reference to Work Order Numbers Preferred Plant Status

Overhaul History

Links to CM Diagnostic reports and RCA

Tailored Reports and Filtering


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Overview of CM Reporting SysteOverview of CM Reporting Syste


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CM Data & Machine

Information

CM Data & Machine

Information- CM Problem & Method, Fault Priority, Date, Work Order,Comments, Condition Summary

- CM Problem & Method, Fault Priority, Date, Work Order,Comments, Condition Summary


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Plant DetailsPlant Details

- Overhaul History, Lube Quality Targets, Lube Schedule,Report Links

- Overhaul History, Lube Quality Targets, Lube Schedule,Report Links

Direct Link to

Diagnostic Reports

or RCA


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CM Problem Detail & HistoryCM Problem Detail & HistoryDirect Link toCM Software


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Plant Condition SummaryPlant Condition Summary

No Problems4. Good

(1 x Med Priority)3. Acceptable

(2 x Med Priority) but (1 x High Priority)2. Warning

(2 x High Priority)1.Critical

Criteria for Default

Condition Assessment

Plant

ConditionSummary

! Condition Summary is calculated but can bemanually selected and comments added.


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Definition of AlarmsDefinition of Alarms

! Critical: Highest priority. Plant fault requires one ormore of the following:

Shut down plant to correct fault

Corrective action to be scheduled Closely monitor to diagnose the cause of

fault and then schedule corrective action(short period).

!Warning: Medium Priority. Plant requires regularmonitoring (routine or more frequent)to trend problem. Plant is operating in alarm level but

there is no immediate danger by operatingthe plant.

! Acceptable: Low Priority. Plant is in alarm level but onlyrequires routine monitoring and no immediateaction. A problem is suspected but is still in

early stages of diagnosis.

!

Good: No problems identified on plant.


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CM ReportsCM Reports

! Monthly Report

Summary of Plant Problems for the month aswell as Plant Condition Summary

! Detailed Reports

Can provide more information based on filtersand search criteria

Search by Plant Item(s), CM Method,Status, Priority, Date etc...

! Preferred Plant Status Report

Required for plant with standby (backup)


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Preferred Plant Status ReportPreferred Plant Status Report

! Report produced for Production as arecommendation from Engineering & Maintenance

on which plant to operate based on plant conditionmonitoring.

! Maintenance Philosophy involves running the

poorest condition plant when standby plant isavailable (providing production is not affected).

! Preferred Status Report is updated as required byEngineering Group but at least monthly.

! Further CM detail can be obtained by Production ifneeded by using the CMR System.


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Preferred Plant Status ReportPreferred Plant Status Report


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Summary of CM Reporting SystemSummary of CM Reporting System

! The system is a tool to assist with machinediagnostics and presentation of information.

! CM Information is used to support assetmanagement.

!

Maintenance statistical information for assetmanagement comes from the MMS & otherengineering reports.

! A Future Aim is to integrate the CM ReportingSystem into the Maintenance Management System,with direct links to asset management plans.


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CM AlarmsCM Alarms

Critical Alarm

Warning Alarm

Spectrum

Alarm

Corrective

Action


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! After downloading data intothe CM software an

Exception Report isproduced for plant with analarm condition.

Overview of Vibration and Oil Analysis Alarms

! CM Software has alarms for vibration and oil analysisdata.

! Exception Report will identify the alarm level, plant, %

change etc

! Alarm data is analysed. CMR database is referenced toshow historical problems, and existing condition assessmentprior to the new fault.

! Assessment determines how to deal with fault (Work Orderor monitor).

! Information recorded in CMR System.


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Vibration Alarm SettingVibration Alarm Setting

! Alarms were set for the vibration software aftercollecting baseline and historical data(approximately 3-6 months). Ongoing continuousreview of alarms at a minimum of 12 monthly.

Alarms include both overall magnitude and

spectrum narrow band alarming for earlyidentification of plant problems.

Semi-automated exception reporting system

established using Condition Monitoringsoftware.

Plant is grouped into categories to allow

groups of alarms of like plant to be changedsimultaneously or individually.


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Vibration Overall or Magnitude

Alarms

Vibration Overall or Magnitude

Alarms! Reference: Standards (ISO or AS), OEMrecommendation, History & experience.

!

Typically set a warning and critical alarm.! Warning: 1st alarm should be 50-100% greater than

the average of the trend (use + 1 standard deviationif necessary)

! Critical: 2nd alarm should be aproximately150-300% greater than the average of the trend or 2 x1st alarm.


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Vibration Spectrum AlarmsVibration Spectrum Alarms

! Mostly use the spectrum narrow band alarms usingstatistical processing.

! Spectrum Warning for gs, mm/s or ESP:

Rolling Element Bearings & Journals Typically use +1 Standard Deviation (68% data) + 100%

from average

Gearboxes: +1 or 2 Standard Deviations (68%-95% data) + 100%

from average

! Significant historical faults may need to filtered out toavoid distortion of data and another reason to set alarmsearly in the life of the plant.


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Vibration Spectrum AlarmsVibration Spectrum Alarms

! Minimum Thresholds (minimum level a narrow bandalarm will use):

mm/s: Ranges from 0.2 0.5 (100-3000rpm)

gs: 0.2 -1.0 (100-3000rpm)

Gearboxes May need a higher minimum threshold in velocity due to

higher noise floor in spectrum.

mm/s: Ranges from 0.2 0.75 (100-3000rpm) gs: 0.2 -1.5 (100-3000rpm)

! Constant Band Width setting = 10 lines of resolution

This means the Minimum spectrum alarm width = (FrequencySpan/Lines of Resolution) x 10

! Low Frequency Cut Off = 1% (of spectrum Fmax)


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Statistical Set UpStatistical Set Up


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Categories: Linking Plant GroupAlarms

Categories: Linking Plant Group

Alarms


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Vibration Alarm Case Study ExamVibration Alarm Case Study Examp

Initial sign

of bearingdefect


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Results of Time Waveform AnalysResults of Time Waveform Analysi


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Figure 11: DRUM DE BEARING INNER RACE.

5 months after initial Identification


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Bearing Fault InvestigationBearing Fault Investigation

! Use of Demodulation and time waveform added toroutine vibration analysis.

! Demodulation spectrum and magnitudemeasurements and alarms added to give earlierindication of a bearing fault.

! Preliminary Investigation into root cause foundbrinelling marks on bearing. Detailed RCAperformed by consultant identified bearing

installation procedure as the cause of the bearingfault.


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Oil Analysis AlarmsOil Analysis Alarms

! Oil types and machines are grouped intocategories as with vibration to allow simultaneousalarm changes.

! Primary Indicators: Overall magnitude alarms based onOil Company recommendations

Viscosity (+ 10%window alarms), Water ppm, TAN,

Oxidation, Nitration

! Elemental (spectrographic) Alarms: Statisticalbased on ASTM Standard D6224

Statistical includes 1 standard deviation from the average oflast 5 readings + 30% offset.

Standard suggest last 6 reading but 5 more effective.

! Additive level alarms based on informationobtained from oil manufacturer

Includes: Phosphorous, Calcium, Magnesium, Zinc,Barium.

-


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Oil Analysis AlarmsOil Analysis Alarms

! Particle Count Alarms (ISO 4406)

Typically range from 18/15/12 to 20/17/14Example For ISO 18/15/12 >4um 18 grade = alarm range 1300-2500 particles/ml

>6um 15 grade= alarm range 160-320 particles/ml

>14um 12 grade= alarm range 20-40 particles/ml


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Oil Analysis Statistical Fault AlarmOil Analysis Statistical Fault Alarm


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After Oil ChangeAfter Oil Change


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Alarm StatisticsAlarm Statistics

Vibration

! 10% of total alarm number initiated after testing (approximately). A typical pumpset will have 12 measurements for vibration.

! 2-3% of total alarms will be genuine faults or problems that needmonitoring

! 7-8% will be from spectrum alarms that are due to: Minor resonance peaks, noise background/cable), plant

operational changes, unidentified frequencies.

Oil

! 10% of plant will have alarms (approximately)

! 5% of alarms will be genuine faults or problems that need

monitoring! 5% due to early initiation because of statistical alarm short comings

with low values.Example A vibration trend change from 2mm/s to 4mm/s is significant.

An Oil analysis trend change from 2ppm of iron to 4ppm isnot as significant but is still a 100% change.


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Undetected FailuresUndetected Failures

! If alarms do not detect a plant fault or failure check:

Frequency of data collection

Method of alarm setting and values

CM methods used.

i.e. include wear debris analysis in routine

oil sample testing or for exceptions Include higher lines of resolution in

vibration readings

Include additional vibration measurementtypes, locations or directions.


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SummarySummary

! Condition Monitoring is an important part of AssetManagement and CM Reporting information isavailable for all stake holders.

! The reporting system has two levels ofcommunication:

Detailed level for CM Practitioners.

Summary Level for other stake holders

! Alarms are a combination of overall and statistical.

!

Condition Monitoring information supports the pro-active maintenance approach:

Address the root cause of faults and improveplant performance and availability.

nick lee - cm reporting and alarms

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