Metrix Vibration Monitoring Methodology

Metrix sells value, not just products.

The Metrix Vibration Monitoring Methodology mirrors the Plant’s Return on Investment (ROI) that they derive from the use of our products. 

Introduction

Metrix advocates a vibration monitoring solution that makes economic sense for the machine’s impact on the plant. For critical production limiting machines we advocate a sensor solution that monitors each bearing or throw, thrust and speed on rotating or reciprocating machinery. For non-critical rotating or reciprocating machinery that marginally affects plant production, we advocate a minimal sensor solution for monitoring and protection, or depending upon the asset, an electronic or mechanical switch for protection.

Our solution depends upon the customer’s cost of Unscheduled Downtime. Unscheduled Downtime caused by a problem coming from a rotating or reciprocating machine is the costliest for a plant. The plant loses money from lost profits (Lost Opportunity Cost = loss of profitable output), expedited repair, material and labor costs, standby labor costs, quality issues, customer trust / delivery issues, and most importantly personnel safety concerns.

Metrix Offerings by Customer Value

Metrix Offerings by Customer Value

Metrix Offerings by Customer Benefits

Metrix Offerings by Customer Benefits

Metrix solutions “help” customers to reduce unscheduled downtime, expedited repairs, quality and delivery issues, and safety concerns.

Rotating and reciprocating machines are managed in one of four ways:

1. Run to Failure (worst) – most expensive way to operate. Run the machine until it fails then replace it.
2. Preventative Maintenance (good) – repairs to the machines are made on a periodic basis, regardless of the machines condition. Oftentimes, the preventative repairs are more damaging to the machine than if the machine was left alone – this is the next most expensive way to operate.
3. Predictive Maintenance (better) – repairs to the machines are made based on the condition of the machine, based on predictive technologies like vibration monitoring, thermal imaging and lubrication analysis – this is one of the least costly ways to operate, but needs a consistent investment in permanent monitoring via transmitters integrated with the existing Control System (PLC’s, SCADA, RTU’s, etc.).
4. Proactive Maintenance (best) - repairs to the machine are made based on the condition of the machine, based on predictive technologies like thermal imaging, lubrication analysis, combined with continuous vibration monitoring with data correlation with the plant process parameters of pressure, flow, power level, capacity, etc. – this is the least costly way to operate, but has the highest initial startup cost.

Relative Cost of Unscheduled Downtime

Customers use vibration monitoring to save money!

Customers want to save money and they need vibration monitoring in order to have a Predictive or Proactive Maintenance strategy. With vibration monitoring they have a number of choices. These vibration monitoring choices are as below.

Methods of Vibration Monitoring

1. Walk-Around Periodic (usually monthly) Vibration Data Collection - This is periodic data collection without transient data, and is usually complimented with a Metrix vibration switch (mechanical or electrical) to prevent machine failure between readings.
2. Walk-Around Vibration Data Collection, with waveform and or transient data - Usually performed after the Walk-Around Data Collection program has found a problem or after a Metrix vibration switch has tripped the machine offline.
3. Continuous Vibration Monitoring without waveform and transient data - Typically incorporated with alarm and shutdown capability to prevent machine failure and to easily identify trends – Metrix 5580 / SW5580 with Metrix Sensors or DATAWATCH IX with Metrix Transmitters, or Metrix Transmitters connected directly to the Control System.
4. Continuous Vibration Monitoring without waveform and transient data with process data correlation - Normally incorporated with alarm and shutdown capability to prevent machine failure and to easily identify trends given what is normal to the process conditions – Metrix 5580 / SW5580 with Metrix Sensors or DATAWATCH IX with Metrix Transmitters, integrated by Modbus TCP/IP over Ethernet to the Plant Information Network, or Metrix Transmitters connected directly to the Control System which has been connected to the Plant Information Network.
5. Continuous Vibration Monitoring with process data correlation - Routinely incorporated with alarm and shutdown capability to prevent machine failure and to easily identify trends. This also provides the ability to perform machinery diagnostics by having the proper transducer suite on the machine – The vibration, thrust, speed and or impact data is incorporated with the Control System process data.
6. Continuous Vibration Monitoring with waveform and transient data with process data correlation - Generally incorporated with alarm and shutdown capability to prevent machine failure and to easily identify trends given what is normal to the process conditions. This also provides the ability to perform machinery diagnostics on demand – Vibration Monitoring System (e.g. Setpoint, BN 3500, etc.) with Metrix sensors, integrated via plant process data historian.

Customers monitor rotating and reciprocating machinery for vibration for a number of reasons:

1. Safety of personnel and surrounding equipment.
2. Prevent catastrophic failure of equipment.
3. Provide alarm and shutdown capability to prevent catastrophic failure.
4. Provide early warning of equipment problems so maintenance can be planned.
5. To avoid unplanned maintenance and unplanned plant/facility shutdowns.
6. To save money!

The Method of Vibration Monitoring is determined by the return on investment (ROI) usually measured in terms of Compounded Annual Rate of Return (CARR).

Rotating and Reciprocating machinery Return on Investment (ROI) is determined by a number of factors, the biggest of which are the Average Cost of Repair and the Lost Opportunity Cost due to unscheduled downtime. Depending upon the process the Lost Opportunity Cost can far outweigh the Average Cost of Repair. The solution Metrix provides should provide a (ROI) of two times the cost in less than three (3) years for avoiding just one Unscheduled Repair, for a Compounded Annual Rate of Return (CARR) of 26%. Here are some examples:

150 Megawatt Combined Cycle Gas Fired Power Plant Example

• In order for the plant to operate the critical equipment has to operate. For example the Gas Turbine, the Steam Turbine, their associated generators, the Feed Pump, the condensate pumps, the cooling system, etc.
• The margin on 1 megawatt-hour (MW-hr) of electricity is at a minimum $45 USD / MW-hr sold to wholesale customers (this is a $0.045 USD per kW-hr rate). So one hour of unscheduled downtime equates to a Lost Opportunity Cost of $6750 (150 MW-hrs/hour x 1 hour x $45/MW-hr = $6750). One day of unscheduled downtime results in a Lost Opportunity Cost of $162,000 per day ($6760/hour x 24 hours = $162,000).
• Customer Value = Repair Cost + Unscheduled Downtime = + $162,000 minimum per day.

Note: Components within the combined cycle plant may be redundant or if unavailable may reduce plant capacity, like the condensate pumps, cooling water pumps, cooling tower fans, etc., so they have less of a financial impact on the plant. For example let’s assume that if a cooling tower fan is out of commission that the plant capacity is reduced by 5%. That would mean that the Customer Value is 5% of the values calculated above or $8,100 per day ($162,000/day x 5% = $8,100).

In other words, the Gas Turbine, the Steam Turbine, their associated generators, and the Feed Pump may easily justify Full Metrix Transducer Suite of Sensors (XY Bearing Vibration, Thrust, Speed and or Impact) with full integration to the Plant Information System, whereas the condensate pumps, cooling water pumps and cooling tower fans would justify the one or two Metrix transducers and possibly the Metrix 5580 / SW5580 or DATAWATCH IX Solution integrated to the appropriate Control System and Plant Information Network.

Small Natural Gas Pipeline Reciprocating Compressor Station Example

• Natural Gas Pipeline Compressor Station – Capacity 92,000,000 cubic feet per day (2,600,000 cubic meters per day) – 100% of flow is through the reciprocating compressor.
• The margin on 1000 cubic feet of Natural Gas is $0.48 USD for sales to an Industrial Customer.
• One day of downtime results in $44,160 in Lost Opportunity Cost ($0.48 x 92,000,000/1000 x 100% = $44,160).
• Customer Value = Repair Cost + Unscheduled Downtime = + $44,160 minimum per day.

Note: If the pipeline capacity is 10 times larger (not uncommon for larger pipelines), the Lost Opportunity Cost is 10 times higher.

This small Natural Gas Pipeline Reciprocating Compressor would easily justify the Metrix 5580 / SW5580 with Metrix Sensors or Metrix DATAWATCH IX / Transmitter Solution integrated to the Plant Information System, whereas, it may be difficult to justify a VMS with Metrix Sensors with full integration to the Plant Information System for this small facility. Other larger reciprocating compressor stations could easily justify a full Metrix Suite of Sensors with full integration to the Control System and Plant Information Network.

Why choose Metrix?

Metrix provides value by reliably providing information when you need it, at the least possible cost while at the same time giving you early warning of machine malfunctions. Metrix Methodology makes vibration monitoring easy by recognizing the fact that most of your machines are running well. You only need to worry about the exceptions. 

For example, only our solution can help you fix a phase trigger when the machine is operating! There is no other comparable solution available today that can help you fix this problem when the machine is running. Any other solution would likely require you to have an unscheduled downtime, or extend your downtime on startup.

We can reduce your spare parts inventory by our unparalleled 5 day lead times so that you can complete your system installation on time without loss of production. Take advantage of our SIL and Hazardous Area Ratings.  Reach out to us, we look forward to serving you.