In today’s blog we will be discussing the basics of a vibration monitoring program and benefits for your plant. The rotating equipment used in a plant is essentially the heartbeat of the plant. Rotating equipment is used to move gases and liquids throughout the plant, allowing the different production process units to perform their intended duties. To provide the desired on-stream production rates of these units, the rotating equipment must be reliable. Maintaining the equipment’s reliability at the desired high level is a process that requires many different people’s abilities and skills.
You get a report from a plant operator that a piece of rotating equipment seems to be vibrating more than it has previously been and wants to know what to do. How do you make the judgement call to continue its operation or to shut it down? Well, let’s start off with a little history searching… Do you have a routine or continuous vibration monitoring program that has been monitoring this piece of equipment and if so, what are the characteristics of the vibration data history? Does your company have the ability to perform a spot vibration data collection and analysis for that equipment to check its current condition? Knowing the history of this equipment, being able to perform a current vibration analysis on the equipment and having a program with defined vibration levels with corresponding actions will provide the information to determine if the equipment can continue to operate or whether it requires immediate shut down and repair.
Now, let’s step back and ask about that routine, continuous and spot checking vibration monitoring capability? As part of your plant’s condition based programs, it would be expected to have a plan for the vibration monitoring of the rotating equipment. Monitoring of the equipment’s vibration signature (frequency and amplitude) assesses the “health” of the equipment. Evaluations of this monitoring data is typically completed on a routine basis, continuous basis and also spot checking when the equipment’s vibration level has elevated. The benefit of monitoring is to first provide a high level of safety to the plant and personnel and then to minimize equipment failures that may lead to a serious event or even worse, injury or loss of life.
Rotating equipment typically has some level of vibration and with changing operational conditions or changes within the equipment, the vibration signature changes. The goal of a well-developed vibration monitoring program is to be able to identify the vibration frequency and amplitude to associate it with a defined situation. This evaluation provides the ability to determine whether to continue to allow the equipment to remain in service, plan a “short in the future” equipment shut down or an immediate shut down for maintenance. Goals for any of the condition monitoring programs should be specific and measurable. To ensure that the program is providing the expected benefit, key performance indicators (KPI’s) should be established and tracked.
Rotating equipment included in the program should include all critical (typically unspared equipment that can cause business interruptions/losses) and non-critical (typically equipment that does not greatly affect business losses). Rotating equipment typically included in the program are compressors/blowers, fans, pumps, motors, gearboxes, steam/gas turbines and engines. The extensiveness of the programs for each type of equipment may vary. Managing the vibration monitoring program must consist of training, procedures, records and program reviews/audits.
Actions to Take:
1) Review to determine if your plant has a vibration monitoring program.
2) Review your current vibration monitoring program.
3) Determine what equipment is included in your current vibration monitoring program.
4) Review your vibration monitoring program’s goals & associated KPI’s.
If this seems overwhelming or you need help, BoilerRock can assist with the establishing, identification, development, monitoring or auditing of the vibration monitoring program that can benefit your plant.
Terry Roehm is a Rotating Equipment Specialist with 40+ years experience in both the upstream and downstream businesses of the Oil and Gas Industry. He is a member of the American Petroleum Institute (API) serving on task forces for the mechanical subcommittee and is a past advisory committee member for the Texas A&M Turbomachinery Symposium. He has held various positions in maintenance and engineering involving specification, selection, procurement, testing, installation, startup, troubleshooting and turnaround planning for the rotating equipment. He has established programs, provided and developed training opportunities and has completed audits for companies to improve their operating and maintaining of rotating equipment. He has a Mechanical Engineering Degree from Purdue University and is a registered Professional Engineer in the states of Kentucky and Texas.