Introducing our latest post on Remote Monitoring and Diagnostics - a comprehensive guide to enhancing efficiency and performance through remote monitoring technology. Explore the benefits and advantages of this cutting-edge solution in our latest blog article.
Hello, PESS seems intriguing, but it is not the one I was referring to. - V.Narayan
I tried searching the Bkhome website but could not find any information on online monitoring. Thank you.
- 13-02-2025
- Frances Fisher
The utilization of integrated systems has led to a significant decrease in the demand for standalone vibration monitoring systems. Vibration monitoring is now seamlessly integrated into Distributed Control Systems (DCS), with some systems still offering 1X extraction capabilities. In response to this shift, many manufacturers of vibration monitors have diversified their offerings to include performance monitoring solutions. For more insight into these evolving product ranges, consider exploring the websites of reputable vibration monitor manufacturers such as SKF, Bently Nevada, and CSI.
When evaluating the effectiveness of these systems, it is recommended to seek feedback from end-users rather than vendors. Visiting the sites of these end-users can provide valuable insights into the advantages and disadvantages of different monitoring systems. Additionally, keep in mind that it is easier to incorporate such systems into newly constructed plants. If you are upgrading an existing plant, consult with on-site personnel and end-users who have experience with retrofitting monitoring systems.
What cost benefit analysis can be conducted for integrating online vibration monitoring into a system, and for which types of industrial plants would this be most suitable? Best regards.
- 13-02-2025
- Victor Thompson
A quick Google search for B&K Denmark Compass led me to this page on Compass, the system I mentioned before. This advanced system can analyze vibration and process data, use algorithms to forecast failure times based on your specific settings. The Bruel & Kjaer website link to the Compass 6000 OPC client is provided for more information: http://www.bkvibro.com/db/files/compass_6000_opc_client.pdf. With its web-based platform, remote monitoring becomes possible with sufficient bandwidth. - V.Narayan.
Implementing online vibration monitoring as part of an integrated system can provide cost benefits for various types of industrial plants, such as oil and gas facilities, petrochemical plants, and large power stations. Online vibration monitoring involves standalone vibration monitors connected to transducers on machines, which raise alarms when vibration levels exceed a certain threshold. These systems are crucial for machine protection and are considered primary safety systems in large machines.
In addition to machine protection, online vibration monitoring systems can also provide valuable data such as trends, spectra, orbits, bode plots, and polar plots. It is important to utilize this information effectively to maximize its value. However, it is essential to note that the cost benefit of these systems may vary, as there are few experts who can interpret the data accurately.
In some cases, integrating vibration signals into existing control systems, such as the Distributed Control System (DCS), can be a more efficient approach. By treating overall vibration as just another parameter alongside temperature and pressure, changes can be easily identified and managed. This consolidated approach can save space in the control room and streamline monitoring processes.
While some companies may invest in elaborate online monitoring systems, it is important to consider the long-term maintenance and usability of such systems. In some instances, companies may find that these systems do not provide significant value to their operations and may choose to remove them. It is crucial to evaluate the practicality and effectiveness of online vibration monitoring systems before investing in them.
Could it be that the operating system you mentioned is of the Unix variety, Buzz?
Buzz, thank you for your response. I found it quite intriguing. It seems like you have had some mixed results with the costs and benefits of online performance monitoring. It appears that in one instance, you saw no benefits and were glad to discontinue it, while in another case, the information gathered remained unused. Have you considered exploring ways to utilize this information more proactively instead of only reacting after the fact? Would you recommend online performance monitoring to others based on your experiences? I have been involved in various projects related to this topic and have also researched others. For example, I am familiar with how Transco in the UK significantly reduced maintenance costs through the use of these technologies. Do you believe there is potential for your organization to achieve similar results, or is online performance monitoring viewed as a wasted opportunity there? Best regards,
- 13-02-2025
- Vanessa Carter
I believe that implementing online monitoring systems is beneficial, but it is essential to have the necessary infrastructure and expertise in place. These systems are most effective when integrated into a well-established condition-based maintenance (CBM) framework that includes analysts, data collection, and predictive maintenance practices. It is crucial to have credibility in identifying critical issues and understanding the implications of any changes.
With an increasing number of MBAs overseeing production areas, there is a potential shift towards automated processes, potentially leading to inefficiencies. Implementing a system to feed signals to the distributed control system (DCS) is a good strategy, but it is important to remember that the DCS primarily falls under the operations department. Having a knowledgeable board operator who understands maintenance is essential for success.
While a DCS is valuable for analysis, it is often utilized after the fact. It is important to have a proactive approach to maintenance and monitoring to prevent issues before they occur.
It seems that in one instance, you encountered a situation where a significant amount of money was spent on gathering and analyzing vast amounts of information that ultimately proved to be of little value. The system eventually failed, making it challenging to justify the cost of replacing it. On the other hand, there are cases where valuable information remains unused. The data collected by a DCS is always put to use, especially in identifying and investigating issues. The ability to compare trends can be a crucial tool in problem-solving. Do you believe there are proactive ways to utilize this information rather than waiting for issues to arise? Ultimately, the effectiveness of these systems depends on how well people are trained to use them. Without proper training or a user-friendly design, the potential benefits of the system may be wasted. For example, there was a situation where a compressor failure could have been avoided if the recorded data had been properly analyzed. Would you recommend online performance monitoring to others based on your experiences? While the concept is beneficial, finding a system that truly adds value and benefits the user rather than the vendor can be challenging.
In many cases, the gradual decline in performance can be monitored through periodic checks or calculations. However, sudden drops in performance are more noticeable and may require immediate attention. I have seen firsthand how technologies like those implemented by Transco in the UK can greatly reduce maintenance costs. Is there potential for your organization to achieve similar results, or is it perceived as an unnecessary expense? Many machines will always require some level of maintenance regardless of the technology used.
Transco managed to streamline their maintenance processes by adopting new technologies that allowed for a more efficient allocation of resources. This shift in approach triggered a reevaluation of their maintenance practices, leading to the elimination of unnecessary tasks. Integrating performance data into the DCS can be beneficial, but it is essential to have dedicated operators who understand the maintenance aspect. Operations personnel often serve as the first line of defense in identifying potential issues, making their input invaluable in the overall maintenance efforts. Building strong collaboration between operations and maintenance teams is key to fostering a productive work environment. Actively engaging with operations staff on a daily basis can help identify issues early on and address concerns promptly, fostering a culture of proactive maintenance management.
Embracing proactive strategies is essential in achieving success in the business world. I wholeheartedly believe that sitting idly in an office, waiting for opportunities to come knocking at your door, is not an effective approach. Take the initiative and seek out opportunities actively - that's the mindset I follow for success!
I was introduced to the world of condition monitoring back in the mid-1960s when a maintenance manager expressed the need for a more efficient way to maintain steam turbine generators. This realization sparked our development of Valves Wide Open tests, which were later standardized in an ASME Code. The method requires specialized test instrumentation and may be too costly for frequent use. However, at a recent conference (ICOMS2005), we shared our success with using Distributed Control Systems (DCS) for effective condition monitoring on a 500MW unit. A copy of the related paper is attached for reference. Join us at the World Congress on Engineering Asset Management in Australia in July 2006 for more discussions on this topic. For more information, visit http://www.wceam.com. - Ray Beebe Attachment(s): Beebe_turbs-018.pdf (154 KB) Version: 1
How can we explore the impact of technology on reducing maintenance efforts? Specifically, I am curious to understand whether the implementation of technology has led to a decreased maintenance workload or if it has prompted a reevaluation of existing processes, resulting in the elimination of unnecessary tasks. With my experience in various projects, such as the case of transco in the UK, I have seen significant maintenance reductions achieved through technology adoption. Is it feasible for your organization to replicate similar outcomes, or is it perceived as a daunting task?
I tend to be skeptical, as machines typically require maintenance regardless of technological advancements. Could you provide examples of how transco effectively minimized their maintenance tasks with technology? What unique strategies did they implement to achieve these reductions - did the adoption of new technology prompt a thorough assessment of operational procedures, leading to the elimination of redundant tasks?
- 13-02-2025
- Heather Coleman
I am not familiar with transco, but I have had valuable experiences with condition monitoring (CM) on crucial equipment like steam turbines. One instance involved a new 350MW machine that had been running for 2 years. I conducted VWO tests early on, even before the warranty tests. The OEM site manager recommended an overhaul, which puzzled the plant manager, my former CM mentor. The machine ran for 17 years before maintenance was required on its HP-IP casing, with CM being utilized throughout. I have also witnessed production losses due to arbitrary operating limits set by the OEM, which could often be adjusted without compromising the plant's integrity or lifespan. A memorable quote from a GM a decade ago resonates with me: "I do not see a compelling technical or economic reason for this modification." This pertained to a proposed major component change from a different OEM.