timken bearing diagnostics and prognostics using pi reducing unplanned downtime rich browner -...

TIMKEN

Bearing Diagnostics and Bearing Diagnostics and Prognostics Using PIPrognostics Using PI

Reducing Unplanned DowntimeReducing Unplanned Downtime

Rich Browner - Program ManagerRich Browner - Program ManagerReliability SolutionsReliability Solutions

The Timken Company, Torrington OfficesThe Timken Company, Torrington Offices

59 Field Street59 Field StreetTorrington, CT 06790Torrington, CT 06790(860) 626-2699 Phone(860) 626-2699 [email protected][email protected]

TIMKENOSIsoft User Conference 2003San Francisco

Company BackgroundCompany Background

Leading bearing company in the Leading bearing company in the U.S.U.S.

3rd largest bearing company in 3rd largest bearing company in the worldthe world

Torrington Company recently Torrington Company recently acquired from Ingersoll-Randacquired from Ingersoll-Rand

Timken now offers the most Timken now offers the most comprehensive array of bearing comprehensive array of bearing products on the market todayproducts on the market today


New Business OpportunityNew Business Opportunity Help our industrial customers derive more Help our industrial customers derive more

value from their rotating equipmentvalue from their rotating equipment Suite of product-services to help end users Suite of product-services to help end users

select, install, operate and maintain select, install, operate and maintain bearings more effectivelybearings more effectively

Enabled by the new communications Enabled by the new communications infrastructureinfrastructure

Bearing reliability dataBearing reliability datais key to success is key to success

Ensure Bearing Failure Does Not Cause Unplanned Shutdowns

Managed by PI


Identified MarketsIdentified Markets Need identified in the process Need identified in the process

industriesindustries CharacteristicsCharacteristics

Capital intensive processesCapital intensive processes Bearings are a major component of Bearings are a major component of

machine efficiencymachine efficiency Cost of bearing low compared to cost of Cost of bearing low compared to cost of

equipment downtime or failureequipment downtime or failure Improvements in operating efficiency Improvements in operating efficiency

translate into translate into top-line growthtop-line growth Key operating goal is to maximize Key operating goal is to maximize

utilization of rotating equipmentutilization of rotating equipment


Un-Served NeedUn-Served Need

Current situationCurrent situation Knowledge of current equipment health Knowledge of current equipment health

is typically lacking is typically lacking Future situationFuture situation

Accurate predictions of equipment Accurate predictions of equipment failurefailure

Serving that need requires:Serving that need requires: Qualified Qualified real-time diagnosisreal-time diagnosis of bearing of bearing

conditioncondition Accurate Accurate prognosis prognosis of future bearing of future bearing

performanceperformance


Anticipated BenefitsAnticipated Benefits

Prior knowledge of the need for Prior knowledge of the need for equipment maintenance will:equipment maintenance will: Increase uptime and throughputIncrease uptime and throughput Reduce maintenance and repair costsReduce maintenance and repair costs Improve product qualityImprove product quality

Benefits from reduced costs:Benefits from reduced costs:

Reduced CostsReduced Costs

Increased SalesIncreased Sales

Top-Line GrowthTop-Line Growth


Role of PIRole of PI PI manages critical condition dataPI manages critical condition data

Real-time process data (load, temp, Real-time process data (load, temp, pressure, flow)pressure, flow)

Condition data (vibration & acoustic Condition data (vibration & acoustic emissions – 1,000’s of values in arrays)emissions – 1,000’s of values in arrays)

Lubricating oil data (wear debris, Lubricating oil data (wear debris, moisture, condition – 1,000’s of values moisture, condition – 1,000’s of values in arrays)in arrays)

PI provides the connectivity within PI provides the connectivity within the information infrastructurethe information infrastructure

Industrial Evolution enables us to Industrial Evolution enables us to manage equipment health remotelymanage equipment health remotely


Assembling the SolutionAssembling the Solution Tools already exist - need to be assembled Tools already exist - need to be assembled

and applied to and applied to prognosisprognosis Timken working with a team of industry Timken working with a team of industry

experts and products to accomplish this experts and products to accomplish this objective:objective: TechAlerts from Macom – oil debris monitoring TechAlerts from Macom – oil debris monitoring

sensorssensors SS22NAP from RLW – local intelligence platformNAP from RLW – local intelligence platform EXP reliability software from Ivara – manages EXP reliability software from Ivara – manages

total asset healthtotal asset health PI from OSIsoft – manages real-time data and PI from OSIsoft – manages real-time data and

makes it available where neededmakes it available where needed AnyWhere/AnyTime from Industrial Evolution – AnyWhere/AnyTime from Industrial Evolution –

provides remote access for monitoring teamprovides remote access for monitoring team Diagnostic/Prognostic software from Impact Diagnostic/Prognostic software from Impact

Technologies – assesses bearing healthTechnologies – assesses bearing health


Technical SolutionTechnical Solution Local intelligent diagnostics and Local intelligent diagnostics and

prognostics module with wireless accessprognostics module with wireless access Modularized, open architectureModularized, open architecture

Enables system to be configured for specific Enables system to be configured for specific needs of an individual application and userneeds of an individual application and user

Intelligence located near the monitored Intelligence located near the monitored assetasset Large volumes of raw vibration data translated Large volumes of raw vibration data translated

into smaller volume of meaningful informationinto smaller volume of meaningful information Qualified diagnosis of equipment health and Qualified diagnosis of equipment health and

remaining useful life performed continuously in remaining useful life performed continuously in real timereal time

Diagnostic information transferred and Diagnostic information transferred and stored in PI for local and remote stored in PI for local and remote managementmanagement


System ArchitectureSystem Architecture

Reliability Centered Maintenance (RCM)

Software“EXP”

Reliability Centered Maintenance (RCM)

Software“EXP”

Sensors

Data Storage &

Management “PI”

Data Storage &

Management “PI”

Remote Data Access“AnyWhere/AnyTime” – Industrial Evolution

Remote Data Access“AnyWhere/AnyTime” – Industrial Evolution

LocalWireless Network

IP-SecVPN

Tunnel

Field Local Management

Remote Management

Data Acquisition & Analysis

“S2NAP”

Data Acquisition & Analysis

“S2NAP”

Bearing Prognostics“Health Index”

Bearing Prognostics“Health Index”

Oil

Deb

ris &

M

oist

ure

“Tec

hAle

rt”

Vib

ratio

n

Pro

cess


OSIsoft Technology UsedOSIsoft Technology Used Data pushed by SData pushed by S22NAP every minute NAP every minute

in XML formatin XML format Data received and parsed and stored Data received and parsed and stored

into PIinto PI 7,500 data points collected each 7,500 data points collected each

time - includes 9 arrays of 500 pointstime - includes 9 arrays of 500 points MDB and ACE used to deploy the MDB and ACE used to deploy the

Impact Technologies “Health Index” Impact Technologies “Health Index” applicationapplication

ICE and MS-Excel used for viewing ICE and MS-Excel used for viewing the diagnostics and prognosisthe diagnostics and prognosis


System CapabilitiesSystem Capabilities

Vibration sensingVibration sensing Broadband Broadband

analysisanalysis High-frequency High-frequency

narrowband narrowband analysisanalysis

DemodulationDemodulation

Oil analysisOil analysis Wear debrisWear debris Moisture contentMoisture content Oil conditionOil condition

Process dataProcess data

Data acquisitionData acquisition Data analysisData analysis

Advanced Advanced diagnosticsdiagnostics

PrognosticsPrognostics Decision supportDecision support

Wireless data Wireless data transmissiontransmission

Connectivity via PIConnectivity via PI LocallyLocally To enterprise To enterprise

managementmanagement RemotelyRemotely


Prognosis

• Multiple sensor input provides improved diagnostic indicators and reduced false alarms

• Combined feature/model provides more accurate prognostics

Diagnostic/Prognostic ApproachDiagnostic/Prognostic Approach


Enabler for Improved ReliabilityEnabler for Improved Reliability

Service implements advanced Service implements advanced maintenance practices using RCM maintenance practices using RCM methodologymethodology Makes intelligent operational decisions based Makes intelligent operational decisions based

on knowledge provided by this systemon knowledge provided by this system Enables comprehensive reliability services on Enables comprehensive reliability services on

rotating equipment rotating equipment Facilitates reduced maintenance activityFacilitates reduced maintenance activity Allows operators to focus more energy on their Allows operators to focus more energy on their

core businesscore business

Timken will Improve the Reliability of Your Equipment


Remote AccessRemote Access Uses Industrial Evolution web hosting Uses Industrial Evolution web hosting

capabilitycapability People remote from the bearing can view People remote from the bearing can view

results and analyze dataresults and analyze data Plant personnelPlant personnel Timken personnelTimken personnel Macom, RLW & Impact Technologies personnelMacom, RLW & Impact Technologies personnel

This will:This will: Increase the robustness of our diagnostic and Increase the robustness of our diagnostic and

prognostic capabilitiesprognostic capabilities Allow us to monitor customers’ equipment status Allow us to monitor customers’ equipment status

in real time from anywherein real time from anywhere Enable our field service engineers to perform Enable our field service engineers to perform

maintenance at the facility more effectivelymaintenance at the facility more effectively Improve product designs for longer life and Improve product designs for longer life and

increased serviceabilityincreased serviceability


Screen shots

from our demo

system:

www.osiso

ftdemo.c

om


Double-click for an

ad-hoc trend


Enter new time period if required, and “Apply”


Click to download data

to spectrum analysis

spreadsheet


Select a time period and

“Finish”


Vibration and oil debris

distribution data populates spreadsheet

and analysis is performed

automatically


Click to view oil debris analysis


Minimize or scroll down to

see Mass Accumulation

trend


Click to personalize

layout


Drag Web parts to desired

locations

TIMKEN

DemoDemo

www.osisoftdemo.comwww.osisoftdemo.com

timken bearing diagnostics and prognostics using pi reducing unplanned downtime rich browner -...

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