2 Predictive Systems Engineering, Ltd Predictive Systems Engineering Diagnostics/Prognostics...

PSE comprehensive system for on-line continuous monitoring of rotating machinery

2 Predictive Systems Engineering, Ltd

Predictive Systems Engineering Diagnostics/Prognostics

Predictive Maintenance Phase Angle/current analysis Vibration Acoustic

Mitigating risk of production interruptions

Automating diagnostics Automating prognostics Automate detection of mechanical and electrical condition Cloud computing Multi-technology approach Integrating diagnostics with CMMS and archive systems

Zero unexpected equipment failures objective Reduced operation losses and maintenance expenditures

3 Predictive Systems Engineering, Inc.

Phase Angle Diagnostics

Voltage

Current

Small variations in the Phase Angle “t” are analysed by PredictiveOnLine proprietary diagnostics. The results indicate the condition of various components in the drive train as well as the electrical condition of the motor. See next slide for an analysis of the frequencies of Phase Angle “t”.

4 Predictive Systems Engineering, Ltd.

Phase Angle Machine Condition Assessment

•Mechanical disturbances in rotating equipment causes small

fluctuations in the moment on the shaft. •The Phase angle of an AC electrical motor is proportional to the

moment on the shaft. •The analysis of the phase angle fluctuations allows PSE to detect and

recognize the mechanical disturbances in the rotating machinery

driven by the electrical motor. •PSE has developed and patented a method for this diagnostics. Its

advantage is that sensors (current transformer) are located in the

motor electrical cabinet and not on the monitored machine itself. •Phase Angle technology is valuable for machinery which is difficult

to access, for low speed machinery, or for machines

operating in harsh environments. •The most important issue is the technology viability. The testing

provided by Mitsui Chemical, Japan, has shown that Phase Angle

Diagnostics is much more sensitive than vibration analysis.

This makes it valuable for all rotating equipment.


Phase Angle Machine Condition Assessmentinstrumentation (eight machines installation)


PAD failure signatures Loose motor foundationsPAD failure signatures Loose motor foundations


PAD failure signatures PAD failure signatures

Pre crystallizer.


PAD failure factor signatures PAD failure factor signatures

Stirred reactor Failure Factor trend


Phase Angle Fractal Phase Angle Fractal


Phase Angle Fractal a useful diagnostic signature Motor torque changes in course of shaft revolution. The analysis of these changes is helpful for diagnostics of electromechanical and mechanical failures in rotating equipment. It is done by building Phase Angle Fractals, which are the polar diagrams of motor torque as a function of rotor angle position. It is an accumulated diagrams obtained in the course of a number of shaft revolutions. The form of a fractal signals machine health conditions.




The fractal in Figure 7 has an elliptical form. This form is associated with some initial abnormality in the bearing.

Figure 7



Figure 8 was registered very close to stirrer outage shows the unstable movement of the shaft inside bearings disclosed by an increased value of fractal dispersion.

Figure 8



The disruption of the fan journal bearings was associated with growing fractal asymmetry.

Figure 10



Figure 10 shows the trend of the fractal diameters ratio in the course of bearing disruption.

Figure 10


Multi Disciplinary Signal Pro-cessing


Diagnostics Prognostics Engineering Report

ereporter

iReporter

http://www.predictiveonline.net/ereporter


Prognostics case story


iDiagnosticsWare functionality

On Line Trend analysis


Machine Status Report

iReporter


PSE - Predictive Maintenance - Technology Summary

THIS DEVICE WILL FAIL IN 8days ± 1 day! CAN YOU BE THAT PRECISE?

THIS DEVICE WILL FAIL IN 8days ± 1 day! CAN YOU BE THAT PRECISE?

CMMS – Computerised Management Maintenance SystemDCS – Distributed Control SystemSCADA - supervisory control and data acquisition

Predictive Maintenance

Assets

PSE

• Monitor rotating machinery; pumps , compressors, fans, gearboxes, mills, etc

• Scheduling and Planning made easy and effective with PSE Predictive Maintenance

• Integrate PSE with CMMS, SCADA, DCS, Pi Historian etc


PSE - Predictive Maintenance - Technology Summary

PSE 's- CLOUD CONDITION MONITORING SOFTWARE

· iDiagnosticsWare – automates failure diagnostics

· Cloud Server Software:

· eReporter – user friendly web based alerts, reports, analysed data

· eExpert – online access to remote expert assistance

· ePredictor – automated failure prediction report

SENSOR NETWORK

· Phase Angle, current and voltage sensors

· Smart wireless 3D accelerometers

· Acoustic sensors

· Zigbee and power line communication

· Cell phone data connection modems

CLOUD ACCESS

· Diagnostics & prognostics

· Monitoring reports

· Remote expert

· SMS and email warnings

OTHER CLIENT/ PSE INTERFACES

· Pi Historian and other archives

· CMMS, DCS, SCADA


Cost Benefit of PSE

Cost Benefit Diagnostics - Chemical Plant Israel

· US$210,000 annual savings from extending their maintenance cycle from 12 to 14 months

· Payback time on initial cost of PSE – 1.1 months

· PSE currently monitors the reactor stirrer

Cost Benefit Prognostics - Power Plant NY

• One day of downtime equals $600,000 revenue loss

• Payback time on initial cost of PSE preventing one day of downtime – 4.4 hours.

• PSE is currently monitoring critical pumps and compressors


Benefits of Predictive Maintenance

Maintenance costs reduced by 50%Unexpected failures reduced by 50%Repair time reduced by 60%Parts inventory reduced by 30%MTBF increased by 30%Uptime increased by 30%

Source: Plant Engineer's Handbook – R Keith Mobley – 2001

Predictive vs Preventive Maintenance


Diagnostics prognostics software

Principle Functionality:

On line signal processing related to steady state and transitive processes

System customization by self-learning monitored machine / process behavior at baseline conditions.Aggregation of different tags into Software Diagnostics Sen-sors indicating the performance of specific electricity genera-tion processes and/or machine failures.Automatic trend tracking and the early discovery of minor dis-turbances in the monitored processes and/or equipmentPrognosis of time when a tag or a Software Sensor value reaches a threshhold value.


iReporter

PredictiveOnLine employs an Intelligent User Interface presenting the results of the remote diagnostics & prog-

nostics of the monitored objects.

It includes; animated icons symbolizing the status of a monitored objectthe signatures and trends of key diagnostics indicators

related to the detected abnormality,the abnormality root cause, the time remained to reaching a threshold, etc.


iDiagnosticsWare statistically analyzes the Diagnostics Software

Sensor Trends and detects small changes related to machine health or

process abnormalities

Afterwards, it builds a statistical model of the trend and forecasts when

the trend reaches the thresholds related to “ALERT” or “SE-VERE”

conditions

Disturbance Growth Prognostics:

iDiagnosticsWare- performance analytics tool


Power Station Management Assistant

Operation Schedule


Compressor protection

Direct link to emergencyshutdown PLC through RS485 bus or dry contacts


Failures detected compressors

Compressor valve flutter: spectral analysis of motor current and phase angle.

Compressor valve leakage: ultra sound probes installed on the cylinder heads.

O-rings wear: thermodynamic analysis of temperatures before and after cylinders.

Shaft bearings malfunctions: ultra sound probes

Loose foundation: vibration analysis.

Rod wear: spectrum analysis of motor current & phase angle and vibration analysis

Short windings in electrical motors: Unbalance of motor current

VFD improper performance: spectral analysis of voltage SINEs in three phases

Rotor-stator gap problems: Phase Angle fractals


Failures detected pumps

Impeller imbalanceBlocked impellerCavitationsMisalignmentBearing abnormalities,Loose foundationResonance problemSub-optimal operation and others..


Process Plant Equipment monitored

Steam and Gas Turbines

Boilers Feed Pumps

Air and gas compressors

Electrical motors

Generators

Mills

Condensers

Heat exchangers

Vacuum Pumps, etc.

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