CONDITION MONITORING

Reporting and Alarms

Loy Yang B
Power Station
 Presentation Outline

! LYB Plant Basics

! Maintenance Philosophy
– CM & Diagnostic Methods used at LYB
– Overview of CM Program
! CM Reporting System
! Alarm setting for Vibration & Oil Analysis Data
 Plant 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)
 Maintenance Philosophy
! Overall Asset Management Plan for planning and
maintenance of plant systems (1yr, 5yr & 75yr)
! Plant that is monitored using CM methods have
related maintenance activities based on condition
assessment and not time based. E.g. overhauls,
oil changes, bearing changes etc…
! Continuous improvement and Pro-Active
maintenance is enhanced through groups formed
to tackle specific plant system problems.
– RCA Program implemented
– CMR Group
– Plant Specific Groups (e.g. Mill Group, Boiler
Inspection Group etc…)
 CMR 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 water
removal
! Training for CM Practitioners
! CM equipment budgeting and procurement
CM Proactive Approach
1. Detection
2. Analysis
3. Investigation (RCA)
4. Correction & Improvement (defect elimination)
5. Verification
6. Reporting & Documenting (History)
 Typical CM & Diagnostic Methods
! Vibration Analysis
! Lubrication/Oil Analysis
! Performance Testing
! Ultrasonic noise measurements
! Thermography
! Motor Current Analysis
! PHD Data Historian System
! RCA
 CM Data Management Systems

! Oil, Vibration (data collection), Current Analysis

data is stored using Rockwell Entek Odyssey
software.
! TG set On-Line Vibration Data stored in Bently
Nevada DM2000.
! Pump Performance and Thermography data stored
in other formats.
! PHD Data historian stores process information.
! Exceptions or Faults are recorded in a Condition
Monitoring Reporting (CMR) System, and includes
Work Order numbers and faults detail.
! CMR System is an intranet based reporting system.
 CM Data Management Systems

Pump
Performance

Oil
TG On- Vibration
Line Data Electrical
CM
Reporting
System

PHD Data Thermography

Historian
Overview of CM Program
Management (in-house)
 CM REPORTING SYSTEM
Why was the CM Reporting System
developed?

! A CM Program needs to be managed.

! A CM Program is an Important part of asset
management and information needs to be readily
available.
! Management of the CM Program would be improved if
information was stored and presented in a better
format.
! Complexity of CM information needed to be reduced
for other stakeholders if it was to be considered.
– Production
– Engineering & Maintenance personnel
– Management
! MMS System information access and presentation was
not adequate
 CM REPORTING SYSTEM...
Problems with Previous CM Reporting
! Information on Plant Condition using various CM
methods was available to CM Practitioners only and
was not readily available to other Maintenance or
Production personnel.
! Existing CM Software for Oil, Vibration and Current
Analysis, Performance data did not correlate the
data for a combined plant condition statement or
assessment.
! Monthly Report was produced manually on word
documents.
! Monitoring of Plant problems during early stages
(prior to raising a Work Order) was done on a
dedicated white board.
 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 ONE
reporting 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
Overview of CM Reporting System
 CM Data & Machine
Information
-- CM
CM Problem
Problem &
& Method,
Method, Fault
Fault Priority,
Priority, Date,
Date, Work
Work Order,
Order,
Comments, Condition Summary
Comments, Condition Summary
 Plant Details
-- Overhaul
Overhaul History,
History, Lube
Lube Quality
Quality Targets,
Targets, Lube
Lube Schedule,
Schedule,
Report
Report Links
Links

Direct Link to
Diagnostic Reports
or RCA
CM Problem Detail & History
Direct Link to
CM Software
 Plant Condition Summary

Plant Criteria for Default

Condition Condition Assessment
Summary
1.Critical ≥ (2 x High Priority)
2. Warning ≥ (2 x Med Priority) but ≤ (1 x High Priority)
3. Acceptable ≤ (1 x Med Priority)
4. Good No Problems

! Condition Summary is calculated but can be

manually selected and comments added.
 Definition of Alarms
! Critical: Highest priority. Plant fault requires one or
more 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 regular
monitoring (routine or more frequent)
to trend problem. Plant is operating in alarm level but
there is no immediate danger by operating
the plant.
! Acceptable: Low Priority. Plant is in alarm level but only
requires routine monitoring and no immediate
action. A problem is suspected but is still in
early stages of diagnosis.
! Good: No problems identified on plant.
 CM Reports

! Monthly Report
– Summary of Plant Problems for the month as
well as Plant Condition Summary
! Detailed Reports
– Can provide more information based on filters
and search criteria
– Search by Plant Item(s), CM Method,
Status, Priority, Date etc...
! Preferred Plant Status Report
– Required for plant with standby (backup)
 Preferred Plant Status Report
! Report produced for Production as a
recommendation from Engineering & Maintenance
on which plant to operate based on plant condition
monitoring.
! Maintenance Philosophy involves running the
poorest condition plant when standby plant is
available (providing production is not affected).
! Preferred Status Report is updated as required by
Engineering Group but at least monthly.
! Further CM detail can be obtained by Production if
needed by using the CMR System.
Preferred Plant Status Report
 Summary of CM Reporting System

! The system is a tool to assist with machine

diagnostics and presentation of information.
! CM Information is used to support asset
management.
! Maintenance statistical information for asset
management comes from the MMS & other
engineering reports.
! A Future Aim is to integrate the CM Reporting
System into the Maintenance Management System,
with direct links to asset management plans.
 CM Alarms

Spectrum
Alarm

Corrective
Critical Alarm Action

Warning Alarm
Overview of Vibration and Oil Analysis Alarms
! CM Software has alarms for vibration and oil analysis
data.
! After downloading data into
the CM software an
“Exception Report” is
produced for plant with an
alarm condition.

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

change etc…
! Alarm data is analysed. CMR database is referenced to
show historical problems, and existing condition assessment
prior to the new fault.
! Assessment determines how to deal with fault (Work Order
or monitor).
! Information recorded in CMR System.
 Vibration Alarm Setting

! Alarms were set for the vibration software after

collecting baseline and historical data
(approximately 3-6 months). Ongoing continuous
review of alarms at a minimum of 12 monthly.
– Alarms include both overall magnitude and
spectrum narrow band alarming for early
identification of plant problems.
– Semi-automated exception reporting system
established using Condition Monitoring
software.
– Plant is grouped into categories to allow
groups of alarms of like plant to be changed
simultaneously or individually.
Vibration Overall or Magnitude
Alarms
! Reference: Standards (ISO or AS), OEM
recommendation, 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 deviation
if necessary)
! Critical: 2nd alarm should be aproximately150-
300% greater than the average of the trend or 2 x
1st alarm.
 Vibration Spectrum Alarms
! Mostly use the spectrum narrow band alarms using
statistical processing.
! Spectrum Warning for g’s, 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 to

avoid distortion of data and another reason to set alarms
early in the life of the plant.
 Vibration Spectrum Alarms
! Minimum Thresholds (minimum level a narrow band
alarm will use):
– mm/s: Ranges from 0.2 – 0.5 (100-3000rpm)
– g’s: 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)
– g’s: 0.2 -1.5 (100-3000rpm)

! Constant Band Width setting = 10 lines of resolution

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

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

Statistical Set Up
Categories: Linking Plant Group
Alarms
Vibration Alarm Case Study Examp

Initial sign
of bearing
defect
Results of Time Waveform Analysi
Figure 11: DRUM DE BEARING INNER RACE.
5 months after initial Identification
 Bearing Fault Investigation

! Use of Demodulation and time waveform added to

routine vibration analysis.
! Demodulation spectrum and magnitude
measurements and alarms added to give earlier
indication of a bearing fault.
! Preliminary Investigation into root cause found
brinelling marks on bearing. Detailed RCA
performed by consultant identified bearing
installation procedure as the cause of the bearing
fault.
 Oil Analysis Alarms
! Oil types and machines are grouped into
categories as with vibration to allow simultaneous
alarm changes.
! Primary Indicators: Overall magnitude alarms based on
Oil Company recommendations
– Viscosity (+ 10%window alarms), Water ppm, TAN,
Oxidation, Nitration

! Elemental (spectrographic) Alarms: Statistical

based on ASTM Standard D6224
– Statistical includes 1 standard deviation from the average of
last 5 readings + 30% offset.
– Standard suggest last 6 reading but 5 more effective.

! Additive level alarms based on information

obtained from oil manufacturer
– Includes: Phosphorous, Calcium, Magnesium, Zinc,
Barium.
– Minimum value alarm approximately 70-80% of
 Oil Analysis Alarms

! Particle Count Alarms (ISO 4406)

– Typically range from 18/15/12 to 20/17/14
Example 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
Oil Analysis Statistical Fault Alarm
After Oil Change
 Alarm 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 need
monitoring
! 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 is
not as significant but is still a 100% change.
 Undetected 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 measurement
types, locations or directions.
 Summary
! Condition Monitoring is an important part of Asset
Management and CM Reporting information is
available for all stake holders.
! The reporting system has two levels of
communication:
– 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 improve
plant performance and availability.