ABB Ability AssetInsight™

Fleet Benchmark Report

Customer test test

Site Plant

Date of Report 21.03.2024

Report Type Fleet Benchmark Report

Report Period 11.03.2024 - 14.03.2024

Reference Period 08.03.2024 - 10.03.2024

ABB Service Contact test

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Introduction
This Fleet Benchmark Report generated by ABB Ability AssetInsightTM is provide an overview of the
health status of all rotating assets in the selected fleet within the selected reporting period time
frame. This report is comparing actual status to the reference period of time to provide a relative
benchmark over time, this will provide better understanding if assets had suffered any deterioration
over time.

Report definition
The report provides a periodic high level fleet status overview on the selected time period and asset
fleet of a specific plant. The information given in this report can be used by the Plant Manager or
Asset Manager for further bad actor reporting and analysis. This report can be complemented with
the asset specific Detail Fingerprint Report e.g. whenever an asset in the fleet is indicated with a fault,
then an asset-specific individual Fingerprint report could provide additional details for the individual
asset for maintenance planning.

How to interpret results

This Fleet Benchmark Report provides individual aggregated health status indicators (healthy,
warning, fault) which are derived from the underlying failure mode KPIs and vibration levels for each
asset in the fleet. NAMUR Icons are used to display the aggregated health status indicators. The trend
of the failure mode KPIs is indicated using icons. An upward facing arrow means the value has
increased, which means the aggregated health status is worse than it was before. A downward facing
arrow means the value has decreased, which means the aggregated health status is better than it was
before. A sideways facing arrow means the value is roughly the same, which means the aggregated
health status remained constant.

If for the given reporting period there is not sufficient or implausible measurement data available,
then the report will indicate the relevant asset health information as “no data available”.

Further details can be found in the Glossary chapter at the end of the report.

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Glossary
Abbreviation Explanation

Increase of KPI value trend

An upward facing arrow means the value has increased, which means
the aggregated health status is worse than it was before.

Constant level of KPI value trend

A sideways facing arrow means the value is roughly the same, which
means the aggregated health status remained constant.

Decrease of KPI value trend

A downward facing arrow means the value has decreased, which
means the aggregated health status is better than it was before

Radial Radial vibration measurement on motor body

Tangential Tangential vibration measurement on motor body

Axial Axial vibration measurement on motor body

VFD Variable Frequency Drive

Root Mean Square - square root of the arithmetic mean of the

RMS
squared values.

Measure of the "tailedness" of the probability distribution of a

Kurtosis variable. Equal to fourth standardized moment. Click here for more
details

Difference between the maximum positive and the maximum

Peak to peak
negative amplitudes of a waveform.

Ratio of peak value to the effective value (RMS). Click here for more
Crest factor
details

1x, …, nx n-th harmonic of rotating speed

Phase angle of a specific harmonic obtained during the

Phase
transformation of the vibration signal to the frequency domain

BSF Ball Spin Frequency

BPFO Ball Pass Frequency Outer race

BPFI Ball Pass Frequency Inner race

DE Drive End

NDE Non Drive End

KPIs Key Performance Indicators

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Table of Contents
1. Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2. Plant Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3. Assets in fault state . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4. Assets in fault state details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5. Assets in warning state . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
6. Assets in warning state details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
6.1. Nano Filter HP Pump condition analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
7. Self-Diagnostics System state summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Table of Contents 4
1. Summary

Figure 1. Site Overview with aggregated health status distribution

2. Plant Overview
Location Train Name Motor Name & Status Load Name & Status

SWCC System Compressor A Train Compressor A

SWCC System Compressor B Train Compressor B

SWCC System Nano Filter HP Pump Nano Filter HP Pump

Train

SWCC System RO 2 High Pres Pump RO 2 High Pres Motor RO 2 High Pres Pump
Train

Table 1. Train Overview with aggregated health status in reporting period

1. Summary 5
3. Assets in fault state
No assets found in fault state.

4. Assets in fault state details

No assets found in fault state.

3. Assets in fault state 6

5. Assets in warning state
No assets found in warning state.

6. Assets in warning state details

6.1. Nano Filter HP Pump condition analysis

Power [kW] Speed [rpm] DE Bearing NDE Bearing Sensor Positions

75 3575 6215 0 DE

Table 2. Nameplate data

6.1.1. Overall vibration trend analysis

This chapter provides an overview of the general vibration levels in the reporting period.

6.1.2. Basic failure mode analysis

This chapter provides an overview of the significant failure modes in the analysis data in the reporting
period.

For further vibration spectrum and waveform analysis of the stored data samples please use the ABB
Ability AssetInsight Workbenchtool to interactively plot individual or multiple spectra and waveforms.

KPI Max Value Avg Value Previous Previous Trend

Avg Value Max Value

Table 3. All unhealthy KPIs

Finding

Impact

Recommendation

5. Assets in warning state 7

7. Self-Diagnostics System state summary

Figure 2. Sensor State Summary

Location Gateway Model Status IP address Firmware

SWCC System SWCC_RO_GW100 n.a. Disconnected 172.16.16.100 84

SWCC System SWCC_Compr_- n.a. Disconnected 172.16.16.101 84

GW101

Table 4. Gateway overview

No sensors with issues found.

7. Self-Diagnostics System state summary 8

KPI definition
KPI Explanation Possible failures

Misalignment Misalignment is one of the leading When machines are not properly
causes of machine failure. The rotor, aligned, it can cause excessive stress
coupling or shaft of the monitored on bearings, couplings, and other
machinery is not aligned with the axis critical components, leading to
of rotation. The equipment is premature wear and failure.
misaligned. The condition monitoring Misalignment can also cause excessive
system is assessing the lower vibration, which can further damage
harmonics of the rotational speed to the machine. Additionally, misaligned
detect misalignment in the machine machines may not operate at optimal
shaft or coupling efficiency, resulting in decreased
productivity and increased energy
costs.

Imbalance Imbalance in machines occurs when Imbalance in machines can cause

the center of mass of a rotating part is failure due to several reasons. First, it
not aligned with its axis of rotation. can generate excessive vibration,
This can cause the machine to vibrate which can damage the machine’s
excessively, leading to damage and components. Second, it can lead to
failure of critical components. The KPI excessive wear and tear on bearings
is assessing the lower harmonics of and other critical parts, causing
the rotational speed to detect premature failure. Third, it can lead to
imbalance in the shaft or rotor. misalignment of parts, causing
excessive stress on them. Finally, it
can also cause the machine to lose its
efficiency and accuracy. Imbalance can
lead to reduced productivity and
increased downtime.

Looseness Looseness in machines occurs when Looseness can cause excessive

bolts, fasteners, or other components vibration, leading to damage and
become loose or are not properly failure of critical components. Loose
secured. The KPI is assessing the lower parts can also cause misalignment,
harmonics of the rotational speed to which can further stress the machine
detect loose machine components and lead to premature wear and tear.
(e.g. loose foundation, screws, bolts, Over time, looseness can cause the
etc.) machine to lose its efficiency and
accuracy, resulting in decreased
productivity and increased downtime.

Acceleration The acceleration envelope KPI is a This KPI is indicative for early impact
Envelope normalized KPI representing the analysis in the machinery (e.g. impacts
acceleration envelope peak to peak from bearing faults or cavitation).
trend value in a normalized scale from
0 to 100. This KPI is calculated from
the assessment of the acceleration
measurement signal.

7. Self-Diagnostics System state summary 9

 KPI Explanation Possible failures

Bearing A bearing fault in a machine occurs A bearing fault can cause excessive
when there is damage or wear to the vibration, noise, and heat, leading to
bearing, which is responsible for further damage and ultimately,
supporting and enabling the rotation complete failure of the machine.
of the machine’s moving parts. This
can be caused by various reasons such
as insufficient lubrication, excessive
load, contamination, misalignment, or
incorrect installation. The bearing
condition KPI is evaluated from the
acceleration envelope wave-form for
each measurement to detect bearing
faults (applicable to roller bearings)

Vibration Excessive vibration in machines occurs Excessive vibration can cause damage
when there is an increase in the of the machine’s components, leading
amplitude or frequency of the to premature failure and increased
machine’s movements beyond the maintenance costs. It can also cause
normal operating range. This can be noise and discomfort to the operators,
caused by several factors such as affect product quality, and lead to
imbalance, misalignment, looseness, safety hazards.
wear and tear, or other mechanical or
electrical issues. The KPI is assessing
whether current vibrations (velocity
RMS and envelope peak to peak) are
excessive in relation to applicable ISO
thresholds.

Flow Flow turbulence is a machine failure Flow turbulence can lead to: Turbulent
that occurs when the flow of a fluid flow can cause excessive stress on
through a machine becomes chaotic machine components, leading to
and unpredictable. Turbulent flow can increased wear and tear. This can
occur in many different types of result in premature failure of parts
machines, including pumps, turbines, such as impellers, blades, and
and heat exchangers. The KPI is bearings. Increased noise and
assessing the lower frequencies to vibration: Turbulent flow can cause
determine flow turbulence. increased noise and vibration, which
can affect the comfort and safety of
machine operators and nearby
personnel. This can also contribute to
premature wear and tear on machine
components.

7. Self-Diagnostics System state summary 10

 KPI Explanation Possible failures

Vane Vane failures in fans occur when the Vane failures can lead to decreased
vanes, which are the blades or fins fan performance, increased noise, and
that direct the flow of air, become in some cases, safety hazards.
damaged or worn out. Vane failures Replacing damaged vanes or entire fan
can be caused by several factors such blades may be necessary to restore
as corrosion, erosion, fatigue, or optimal fan performance.
mechanical damage. Corrosion can
occur due to exposure to moisture or
chemical compounds, while erosion
can be caused by the impact of dust,
dirt, or other particulate matter.
Fatigue can occur due to repeated
stress cycles, while mechanical
damage can be caused by improper
handling or installation. The KPI is
Assessing the amplitude of the blade
pass frequency in the vibration
spectrum.

Cavitation Cavitation is a phenomenon that can Cavitation can damage the

occur in pumps when the pressure of components of a pump: The implosion
the liquid being pumped drops below of vapor bubbles generated during
its vapor pressure, causing vapor cavitation also as vibrations which are
bubbles to form. These vapor bubbles caused by cavitation can cause
then collapse when they reach higher damage to the impeller, casing,
pressure areas, creating shock waves sealings, bearings, or the motor and
that can damage the pump’s impeller other pump components, resulting in
and other components. The most increased maintenance costs and
common causes of cavitation are high reduced pump life. Further, cavitation
pump speed, improper design, and can cause a reduction in flow rate and
operating conditions such as high efficiency of the pump, leading to
temperatures or low inlet pressures. decreased performance and increased
The KPI is assessing the higher energy consumption.
harmonics to evaluate cavitation in the
pump fluid.

7. Self-Diagnostics System state summary 11