® SKF Condition Monitoring
Utilizing Vibration Monitoring
As A Planning Tool For A
Predictive Maintenance Program
When San Diego Gas & Electric (SDG&E)
company decided to utilize its vibration
monitoring program as a planning tool for its
predictive maintenance program, we knew
three elements would be the key to success
1. Skilled vibration analysts and
engineers.
2. Easy-to-use automated vibration
instrumentation.
3. Supportive plant managers and
maintenance personnel.
We have established a vibration monitoring
program to trend machine condition. The
program was successful in preventing
catastrophic failures and reducing our forced Figure 1. The portable data collector is used to
outage rate. measure casing vibration and shaft motion
in displacement, velocity, and acceleration.
We expanded our efforts by starting a On a boiler feed pump, for instance, the
predictive maintenance (PM) program. measurements are taken in three directions
Vibration monitoring is used as a planning tool – horizontal, vertical, and axial – at each
bearing location throughout the entire
to determine when machinery should be equipment train.
overhauled, and to ascertain whether
equipment can be operated beyond regularly
scheduled maintenance shutdowns. When
needless machine overhauls can be avoided, These pumps range from 25 HP up to 5,000
there is a significant financial impact from HP. Also included in the program are eighteen
reduced maintenance cost for parts and labor, gas turbines (located throughout SDG&E’s
as well as increased machine availability. service territory), reciprocating compressors,
and gas turbine compressors at two gas
The PM program employs several different transmission stations.
techniques for determining machine condition,
including: lube oil analysis, borescopy, Even though technological advancements in
thermography, and analysis of maintenance software and hardware make it possible to
and operating history. But vibration monitoring expand the role of vibration monitoring, we
was considered the single most important tool considered personnel to be the most important
because it is the most accurate technique for resource for the PM program. Two vibration
analyzing the condition of rotating machinery. analysts, and one vibration engineer, are
The PM program is utilized at SDG&E’s two employed full-time in the vibration monitoring
fossil fuel power plants on turbine generating program. Two other vibration analysts perform
units and major auxiliary equipment. The vibration monitoring part time in addition to
Encina Power Plant has five generating units, nondestructive testing.
and the South Bay Power Plant has four
generating units. These generating units The vibration analysts and engineer brought to
range from 100 to 320 megawatts. the program self motivation and experience in
using electronic instrumentation. The vibration
Auxiliary equipment includes forced draft fans, analysts had previous experience as
induced draft fans, gas recirculation fans, electronics technicians in the U.S. Navy. The
boiler feed pumps, condensate pumps, vibration engineer holds a degree in electrical
Technical Paper circulating water pumps, service water pumps, engineering. These employees have received
CM1010 water treatment pumps, and fuel oil pumps. additional training at SDG&E through in-plant
is notified and the vibration analyst returns to
the machine site within a few days to recheck
®
the vibration condition. For example, during a
routine survey conducted recently at the South
Bay station, the vibration measurements
indicated an increase in vibration on a gas
recirculation fan.
"Utilizing The software for the computer-aided
Vibration monitoring system permits the analysts to
preset alarm vibration values. When the
Monitoring As A vibration value is exceeded, the software flags
Planning Tool the information. In this case, the vibration
amplitude had increases from 1.5 mils to 5 mils
for A Predictive over a three-week period.
Maintenance Figure 2. SKF Condition Monitoring’s Microlog
Portable Data Collector. When the fan was rechecked three days later,
Program" the vibration had increased to 10 mils. The
maintenance supervisor was notified that the
and outside seminars on the use of vibration machine was operating with relatively high
By Scott Furgerson information for analyzing the mechanical vibration, and it was recommended that the fan
Supervisor, condition of rotating machinery. be shut down for maintenance.
Operations Services
Department Portability, ease of use, reliability, and service The support of the plant managers,
San Diego Gas & were the primary criteria in selecting vibration maintenance supervisors, and maintenance
Electric Company monitoring instrumentation for the program. personnel has been the key to the program’s
Based on these criteria, SKF Condition success. Resistance to recommendations by
(Reprinted by Monitoring’s computer-aided portable “corporate” people, who do not have day-to-
permission from P/PM monitoring system, consisting of a Microlog day involvement with the machinery, is not
Technology Magazine) portable data collector and PRISM2 software, uncommon in other utilities.
were selected. The system is IBM compatible.
When SDG&E first stated the PM program and
Previous experience had shown that when recommended certain action on a piece of
instrumentation and software are difficult to machinery, only some of the recommendations
learn how to use, the analysts often won’t use were followed. Now, more than three years
SKF Condition Monitoring the equipment … even though it may be a very
Area Centers
later, every recommendation for the last
powerful tool. maintenance overhaul was followed. The
North and South America The computer-aided portable monitoring confidence and support of the plant personnel
4141 Ruffin Road system employed by SDG&E was very easy to was gained by providing reliable information
San Diego, California 92123 learn and operate. The software, with that they could trust.
USA pulldown menus and help windows, is Our vibration analysts and engineer also
Telephone (619) 496-3400 practically self-explanatory. Even though a conduct one-day basic vibration courses for
FAX (619) 496-3531 manual is supplied with the system, it isn’t
the plant mechanics. Through these courses,
necessary to operate the software.
mechanics gain a better understanding of how
Europe, Middle East, Africa The portable data collector is used to measure their work can affect the vibration condition,
Postbus 2091 casing vibration and shaft motion in life, and operation of the plant’s rotating
5300 CB Zaltbommel displacement, velocity, and acceleration. On a machinery.
The Netherlands boiler feed pump, for instance, the
Telephone (+31) 418-541010 measurements are taken in three directions … The equivalent availability for our generating
FAX (+31) 418-540455 horizontal, vertical, and axial … at each units has averaged 87.1 percent over the past
bearing location throughout the entire five years … due primarily to the cooperative
Asia, Pacific equipment train. A typical equipment train efforts of the plant managers and personnel,
153 Gul Circle, Jurong consists of a motor, fluid drive (hydraulic the skills of SDG&E’s vibration analysts and
Singapore 629610 coupling), and the pump or fan. Each machine engineer, and ease in operating the vibration
Telephone (+65) 861-6922 is surveyed every four to five weeks. instrumentation (the national average for that
FAX (+65) 861-3044 same period in the power industry was 77.9
The data is then reduced for analysis at percent).
SDG&E’s vibration laboratory. The formats
used for analysis include: vibration trends, Since expanding our efforts by starting the PM
vibration spectra, Bode’ plots, polar plots, program two years ago, we have saved
waterfall and cascade plots, and vector plots. $750,000 in maintenance costs through our
The monitoring system software also prints ability to continue to safely operate rotating
reports of points in alarm, points overdue for equipment beyond regularly scheduled
measurement, and points missed during a maintenance overhaul.
CM1010 (Revised 4-97) survey.
Copyright © 1997 by
At the same time, the labor force was reduced
SKF Condition Monitoring, Inc. When analysis reveals a potential problem with 30 percent, mostly through attrition, without
ALL RIGHTS RESERVED a machine, the plant maintenance supervisor sacrificing equipment availability.
