Uncovering the opportunities of the condition monitoring wireless revolution

Pump Centre Conference 2015

International Centre, Telford

Karl Dalton MIMechE

Business Development Manager

Industrial Market

SKF (U.K.) Limited

© SKF Group

Overview of SKF

More than just bearings… “Knowledge Engineering Company”

5 product platforms

Service platform including:

Bearing Installation

Bearing rework

Custom Application Engineering

Plant Asset Management Consulting

Condition Monitoring Products and Services

Condition Monitoring:

Since 1973

Around 2,000 dedicated staff worldwide

© SKF Group

Contents

Background Brief Overview of Wireless market

Machine Condition Monitoring (CM)

Challenges of wireless vibration monitoring Vibration Analysis

Static vs. Dynamic Data

Wireless Standards

Critical pump applications in the Water Industry The customer need

Why Go Wireless

Background

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The Wireless Market Potential

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• “Wireless” is part of our everyday lives…..

• There are a variety of “Wireless” technologies applicable to condition monitoring

• “Wireless” has uses in portable, on-line, and portable/on-line hybrid applications.

• Main customer concerns: Simplicity, Reliability, Security

Wireless Market

© SKF Group

Wireless – where is / should it used?

ISA* control loop

categories 3, 4, 5 only

Power is everything !

Higher the class, the faster the required update

Fast update = low battery life

Process Monitoring

Non-critical control

Slow loops (open loops)

Retrofits

Add wireless to existing instruments

Plant Asset Management

Condition Monitoring

Inspection data management

*International Society for Automation

Category Class Application Description

Safety 0 Critical Critical

Control 1 Closed loop regulatory control

Often critical

2 Closed loop supervisory control

Usually non-critical

3 Open loop control)

Human in the loop

Monitoring 4 Alerting Short-term operational consequence (e.g. event –based maintenance)

5 Data logging and Upload/

Download

No immediate operational consequence (e.g. preventive maintenance)

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What is condition monitoring (CM)

Condition monitoring is the process of monitoring parameters in machines that can indicate a failure condition.

Doing this allows maintenance to be scheduled and performed, before the failure occurs thus increasing reliability & availability.

This is typically more cost effective and safer than allowing the machine to fail.

One of the methods to deploy is vibration monitoring………

Challenges of wireless vibration monitoring

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Vibration Facts of Life…

Static

Components sum together to make up the “time domain signal”

Am

plitu

de

Time

Each machine component generates its own characteristic “vibration signature”

bearing

coupling

gear

mesh motor

rotor

S The “sum” is expressed as a single number or “static” value – e.g. 2.3 mm/sec RMS to a size of

Am

plitu

de

Frequency

FFT Processor

The “dynamic” data”is the whole time domain, later processed to produce a “Spectrum” to a size of

2 bytes of data

4000 bytes of data

vs. Dynamic Data

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Wireless Positioning H

igh

M

inim

al

Sudden Onset Failure

Gradual Degradation

Co

st

of

Lo

st

avail

ab

ilit

y

Time To Machine Failure

Examples:

• Turbines • Compressors • Generators

• Gearboxes • Machine Tools • Conveyor Systems

• Inaccessible Locations • Cooling Tower Fans

• Pumps and motors • Fans

Required Scan Rate Fast Slow

Walk Arounds

Semi-On line

On line

Critical On line

© SKF Group

Wireless Vibration Facts of Life…“Power is Everything”

“Static” data is easy

No different to a temperature, pressure of other process variable

measurement

125° C is 125° C – how hard is that?

“Dynamic” data is not so easy Bandwidth hungry – transmit waveforms and/or FFT

More data means more time to both collect data and transmit

More time means more Power

More power means less Battery life

Vibration Analysts are hard to please …

Multi-channel parallel acquisition preferred

Synchronization to speed

Multiple parameters (e.g. velocity, enveloping etc.)

Multiple frequency ranges of interest

All need Power …

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Therefore its about a Balance between Power & Bandwidth

Satellite

UWB

802.16 3G

2.5G

1G

2G

Po

we

r C

onsu

mp

tion

Co

st/C

om

ple

xity

1 Mb/s 10 Mb/s 100 Mb/s Data Rate

WMAN

802.11a HiperLAN WiMax

802.11g WiFi

WLAN

WPAN

WAN

802.15.4 wHART SP100

Zigbee

820.15.1 Bluetooth

802.11b

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The WirelessHART Standard (IEC 62591)

Utilizes a time synchronized, self-organizing, and self-healing mesh architecture.

The protocol supports operation in the 2.4 GHz radio band using the IEEE 802.15.4 radio standard.

Developed as a multi-vendor, interoperable wireless standard, WirelessHART was defined for the requirements of process field device networks.

The standard was initiated in early 2004 and developed by 37 HART Communications Foundation (HCF) companies that – amongst others – included ABB, Emerson, Endress+Hauser, Pepperl+Fuchs, and Siemens which formed an open, non-profit membership organization.

WirelessHART is a field-proven technology, with more than six years of installed base, over 100,000 devices, over 8,000 networks and currently growing at a rate greater than 30% per year.

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WiFi versus WirelessHART

Why not WiFi ?

Cost effective, standard, widely available network hardware

Plant information level – video, voice, mobile tools, asset tracking

× High data rate – needs more power, shorter battery life

× Clients need to be in range of Access Point (no meshing between field devices)

Why consider WirelessHART ?

Open Standards – multi-vendor interoperability, open interfacing

Plant instrument level – values, status

Low data rate – less power, longer battery life

Self-organizing “mesh” network technology – routing data via neighboring field devices to/from gateway

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Benefits of Wireless in Condition Monitoring

Easy deployment of monitoring to plant areas un-economic to cover

by wired or walk-around solutions:

Avoid cable trays and wiring

Reduced installation time

Reduced project engineering and documentation

A wireless point can be a factor of 8 lower to install than an equivalent ‘wired’ point

Collect data not adequately covered by existing portable walk-around routes:

Insufficient frequency of data collection due to insufficient manpower to collect

data or time available

Monitor machines in areas that are inaccessible, difficult or dangerous to reach

Easy deployment as a temporary service tool

Track suspect problems flagged by walk-around route

Monitor remote locations without having to going to site

Critical Pump Applications in the Water Industry

© SKF Group

Customers needs

• Improve the reliability of assets

• Support a RCM program

• Support existing systems and methodology

• Simple integration with existing system architecture

• Applications where access is difficult (safety or location)

• Intrinsically safe application needs

© SKF Group

Applications for a WirelessHART Solution

Expanding walk-around routes

Collect data automatically and more frequently from plant areas where it is uneconomic or impractical to retrieve data manually.

Troubleshooting

Temporarily install the sensor on suspect equipment to more closely track failing components.

Difficult to reach areas

Collect basic vibration data in locations that are difficult to monitor with fixed wired systems or hand-held devices.

Integration with installed systems

The collect vibration data can be sent to PLC / SCADA typically through a MODBUS interface from the Wireless router.

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High level (close to alarm) picked up by walk-around program

Bearing defect frequencies

Example application: PDM Service Tool

Wireless device quickly installed to automatically collect data hourly, not bi-weekly

Bearing replaced

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CMWA 8800 WirelessHART Sensor

Uses the WirelessHART communication protocol

Compact sensor with small physical footprint

Provides more insight into machine behavior by means of more frequent data collection than walk around programs

Reduced installation costs compared to equivalent wired surveillance systems

Certified to ATEX Zone 0

Available Measurements:

Velocity (mechanical health)

SKF Acceleration Enveloping Filter 3 (bearing health)

Temperature

Overalls, Time Waveform, and Spectrum Data

Up to 5 year battery life

Why Go Wireless ?

© SKF Group

Delivering your reliability needs

Improve the reliability of assets

Support a RCM program

Support existing systems and methodology

Simple integration with existing system architecture

Applications where access is difficult (safety or location)

Intrinsically safe application needs

© SKF Group

Client installation

Application: pump monitoring in an oil refinery in Asia Pacific

ATEX Zone 2 (or Class 1 Division 1) environment.

Dense pump population under metal superstructure.

Hardware

CMWA 8800 wireless sensors were located at selected locations

WirelessHART gateway located outside a Process Interface Building (PIB). Power cable (+24 Vdc) and network cable pulled from inside PIB to the gateway.

Computer and network switch located inside PIB running:

Wireless Sensor Device Manager software to configure/manage the sensors, and communicate with the WirelessHART gateway.

SKF @ptitude Analyst software to store, display and analyze data.

© SKF Group

Sensor placement

© SKF Group 28 April 2015

Slide 25

Setup without routing, 10 sensors

Gateway

10 sensor group

200m

50m

Sensor – routing disabled

Sensor – routing enabled

Solid Obstacle

Solid Obstacle

Overall levels and waveform data reach the gateway

© SKF Group 28 April 2015

Slide 26

Setup with routing, 10 sensors

3 sensor

200m

3 sensor 2 sensor

Sensor – routing disabled

Sensor – routing enabled

Gateway

Overall levels and waveform data reach the gateway

50m

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HART variables to Distributed Control Systems (DCS)

HAZARDOUS AREA

ATEX ZONE 2

ATEX ZONE 1

ATEX ZONE 0

HART Configurator Software

HART OPC Server

Process Control and Information System

Scalar Values Only

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Dynamic Data to the Predictive Maintenance Department

IN PARALLEL

Wireless Sensor Device Manager

CMSW 8800

SKF @ptitude Analyst

SKF XML

HART OPC Server

Process Control and Information System

HART OPC

HART OPC MODBUS

Scalar Values Only

Scalar Values + Dynamic (FFT) Data

© SKF Group

The value of frequent updates …

• Problems with this pump were seen within the first two weeks of installation.

• Previously this pump was only being monitored via a walk around vibration program on a monthly basis.

• With a monthly walk-around data collection, what are the chances of catching this?

Bi-weekly walk-around - No issues detected

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The value of frequent updates

Hourly updates enabled the detection of short periods of process induced high vibration levels.

Velocity & Acceleration Enveloping levels both go up, and both go down again

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Phase 2: Results after 2 months

Clear bearing defect frequencies (BPFO) – recalling the excessive periodic

vibration detected by the system months earlier.

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Summary

System quick to install compared to a wired counterpart.

The typical range in plant, with ‘medium density’ (metal) obstacles, of 50 meters as published was confirmed.

To optimize battery consumption, a practical balance of sensors set as routers, and sensors set as leaf nodes was configured. Dedicated routers were added allowing to configure sensors as leaf nodes, thereby maximizing battery life.

Overall level and time-waveform data could be gathered into SKF @ptitude Analyst from sensors located well over 100 meters away from the gateway using the mesh network functionality.

© SKF Group

Two different customer requirements - One Device

HART variables to DCS

Overall Data

Overall vibration condition required to be trended in the Control Room

CMWA 8800 sensors

Vibration overalls and temperature via HART MODBUS OPC

Dynamic Data

Time-waveform and FFT data to the maintenance department for preventive maintenance programs;

CMWA 8800 sensors

Wireless Sensor Device Manager software

SKF @ptitude Analyst CMSW 7400 version

© SKF Group

I hope you were enlightened by what I said! Interested in exploring further ?.............Great! Please come and chat with us in the exhibitor area