plant maintenance & condition monitoring
TRANSCRIPT
Condition monitoring
By condition monitoring we mean continuous evaluation of the health of plant and equipment throughout its serviceable life.
Condition Monitoring
Condition monitoring (CM) is a process of monitoring a parameter of condition in machinery eg. Vibration , temperature etc.
The scope is to identify a significant change which is indicative of developing a fault.
Condition monitoring is a process which is used to monitor the condition of the machine which ultimately reduces the time required to identify and rectify the fault which further increases the efficiency of the machine.
Condition monitoring provides us the real time information about the condition of the machine which gives us the ability to minimize or to eliminate the factors responsible for occurrence of faults .
Condition monitoring can, in many cases, be extended to provide primary protection, but its real function must always be to attempt to recognize the development of faults at an early stage.
Condition Monitoring
In case of equipment critical to your performance, periodic visits and siteinspections may not be sufficient.
Online system can work fully autonomously to keep monitored machineryequipment.
Online Condition Monitoring
Workforce optimization - IT technology can support the workforce and optimize site personnel.
Fewer gaps in data – OCM ensures data accuracy and provides continuous data collection.
Improved diagnostics – Historical trend data are available to ensure consistent analysis, without trust only on personnel experience.
Data acq.
Data acq.Data
acq.
Maintenance managers should consider the following when choosing a vendor for acondition monitoring solution:
The ability of the solution to scale with evolving needs (support new typesof algorithms, wide variety of I/O and emerging sensors, expand to new systems).
The access to the raw engineering data, to adapt the system to the new and innovativeanalysis techniques and extend the solution to meet the maintenance programrequirements.
Interoperability with third-party hardware and software packages: the solution shouldintegrate with existing CMMS and ERP systems and any data historians or processmanagement enterprise software used.
Scalability of the solution to be adapted and extended to a larger part of fleet assets.
Choose a CMSBefore choosing a condition monitoring system, maintenance managers need tounderstand which assets and which failure modes should be monitored. The decisionsshould be based on the size and number of assets and the types of measurements neededto detect the failures.
Computer Maintenance Management System
Managing the machinery maintenanceis the most essential role of a CMMSsolution.
• Give users immediate overview of
the state of the maintenance needs
• Schedule the maintenance work
order activities
• Provide accurate inventory forecasts
• Provide instant access to hundreds
of invaluable reports
A CMMS is computer software designed to simplify maintenance management. DifferentCMMS solutions offer different types of systems.
Benefits (savings)
Reduction of personnell overtime
Reduction of subsupplier support
Reduced maintenance backlog
Reduction of repairing activities costs
Effective utilization of maintenance personnel’s time
Reduced supervisor follow-up role
A useful step to get the ISO certificate
Remote diagnostic
Remote Diagnostic
• Real time machine data can be easily shared at the same time with field personnel and with remote central engineering HQ.
• The constant collaboration of the entire diagnostic team (field and remote) speeds up the troubleshooting of any kind of anomalies occurred in site.
• Customer plant can also be monitored by a skilled remote diagnostic engineer’s team without the presence of technicians on site.
• Remote diagnostic allows the cost reduction avoiding the presence of the diagnostic team and technicians in site.
• Remote diagnostic is very useful especially for remote and offshore sites.
Features
Customizable
Configurable
Reliable
Portable
Save costing
Multiple monitoring
Remote control access, monitoring, diagnosis
Part of a quality long term service agreement
Monitoring early changes of equipment behavior and supplying proper
maintenance as deemed necessary
Monthly (typical), weekly or daily (if needed) Machine Train health monitoring
reports
Better scoping and planning of next scheduled term maintenance
Additional help when solicited
Optional help from the service provider, when opportune Remote tuning of
control parameters, when such service is appropriate
Applying technical expertise and skills at scheduled term maintenance
and between intervals by remote monitoring:
Borescope inspections
Vibrations data collection and analysis
Remote monitoring and real time performance analysis, with real time plot of
multiple engine health indicators
Combustion Dynamics monitoring and automatic corrective actions
Periodic maintenance
Application
The DasBox Solution
Our team using DASBOXFully developed by GS&S team, based on its long time fieldservice experience, the DASBOX is a server grade PCs,whose function is to gather diagnostic data from differentdata sources for both local and remote data recording andanalysis.
DASBOX is able to manage the main standard industrialprotocols (Modbus, EGD, OPC, etc.) The system has beendesigned to be able to manage all the signals coming fromall field sensors (Pressure transmitter, RTDs,Thermocouples, Voltage/Current probes, Vibration probes,etc.).
It is created in order to enhance plant control andmonitoring during the execution of critical tasks, such asemergency or programmed and non-programmedmaintenance activities, by means of applying the latestavailable technologies.
Functions
System Layout
FrontendA micro-service based set of components
based on modern communication standards.A very lightweight and portable solution Features:
Acquisition:● Process configuration● Real time monitoring with proactive data delivery● Real time elaboration (software scaling, virtual sensors, software alarms)● Data storage into relational database
Elaboration:● Vibration analysis
Visualization:● Browser based, effective and dynamic User interface for displaying reading and trend data● Exploiting modern web features (HTML5, AJAX, Web Sockets)
Interface
Develop a web based frontend able to wrap a solid, multiprotocol and multidevice, production level industrial monitoring kernel
Functional and performance scalabilityComponent based in order to provide
maximum provisioning flexibility Small footprint in terms of disk-space
and memory usage for embedded systems
Browser based, appealing and highly effective User Interface
Start point towards a new model of remote maintenance service
R&D on different aspects Technological● Enabling multi-user collaboration tool for process configuration● Adoption of timeseries databases to optimize data storage● Exploiting more HTML5 technologies (web workers, local storage) to improve user experience even further
Frontend
Functional● Experiment different deployment strategies effectively enabling remote maintenance● Improve analysis process by leveraging data science tools like machine learning and artificial Intelligence
Web site: www.gssnet.euContact: [email protected]
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