Slide 1

AV-25 Rotating Equipment HealthMachine Condition Monitoring-MCM

Victor Lough – Avantis

Co-Authored By:Andy Bates – Artesis(not present for today’s session)

@InvensysOpsMgmt / #SoftwareRevolution

/InvensysOpsMgmt

/InvensysVideos

social.invensys.com

© 2013 Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are proprietary marks of Invensys or its subsidiaries.All third party trademarks and service marks are the proprietary marks of their respective owners.

Victor Lough – Avantis

Co-Authored By:Andy Bates – Artesis(not present for today’s session)

/InvensysOpsMgmt

/company/Invensys Operations Management

Why Progressive Operations?

If you’d had 3 months warning of 5 keyfailures over the past year, how much couldyou have saved?

Loss of production

Cost of spares

Cost of labour

Secondary damage

Opportunity cost

Slide 3

If you’d had 3 months warning of 5 keyfailures over the past year, how much couldyou have saved?

Loss of production

Cost of spares

Cost of labour

Secondary damage

Opportunity cost

Achieving Design Life would be Nice

Second generation

Moubrey recognition that 68% ofequipment is prone to fail early in itslife. So called “infant mortality”.

This led to the popular “bathtubcurve”

Excessive invasion

Unnecessary maintenance

Incorrect Installation

Incorrect commissioning

Bad workmanship

Poor Design

Poor manufacturing

17th April09

23th April09

4th 5th and6th May09

Examine 2

22nd and23rd June09Examine 2

24th June09Examine 2

Slide 4

Second generation

Moubrey recognition that 68% ofequipment is prone to fail early in itslife. So called “infant mortality”.

This led to the popular “bathtubcurve”

Excessive invasion

Unnecessary maintenance

Incorrect Installation

Incorrect commissioning

Bad workmanship

Poor Design

Poor manufacturing

Motor as Sensor Developing faults in the motor or in the

equipment connected to it affect boththe air gap and torsional dynamicsbetween the motor stator and rotor

These sensitive variations change therelationship between the motor inputand the output signals that are thenused to detect and diagnose faults

System is able to use the motor as aneffective sensor for the whole system,without the need for additional specialsensors

Slide 5

Developing faults in the motor or in theequipment connected to it affect boththe air gap and torsional dynamicsbetween the motor stator and rotor

These sensitive variations change therelationship between the motor inputand the output signals that are thenused to detect and diagnose faults

System is able to use the motor as aneffective sensor for the whole system,without the need for additional specialsensors

Equipment covered

Equipment driven by three-phase electric motors Pumps, fans, compressors, conveyors, …

Generator and alternator systems Turbo-alternators, diesel generators, wind turbines, …

Equipment not covered DC motors, single-phase motors, equipment with speed

or load changes exceeding 15% in 6 second period

Slide 6

Equipment driven by three-phase electric motors Pumps, fans, compressors, conveyors, …

Generator and alternator systems Turbo-alternators, diesel generators, wind turbines, …

Equipment not covered DC motors, single-phase motors, equipment with speed

or load changes exceeding 15% in 6 second period

Where deployed?

Oil and gas industry: Centrica, BP,XOM, Hess, BGG, …

Water companies: Wessex, South West, STW, …

Power generation: EPR, eON, Marchwood PS, …

Marine and naval: RN, Maersk, Carnival, Louis, …

Transportation: LUL, BAA, Tubelines, …

Automotive: Leyland trucks, Renault, VWG, …

Food and bev: William Grant, S&N, …

Metals processing: Special Metals, Tata Steel, …

Slide 7

Oil and gas industry: Centrica, BP,XOM, Hess, BGG, …

Water companies: Wessex, South West, STW, …

Power generation: EPR, eON, Marchwood PS, …

Marine and naval: RN, Maersk, Carnival, Louis, …

Transportation: LUL, BAA, Tubelines, …

Automotive: Leyland trucks, Renault, VWG, …

Food and bev: William Grant, S&N, …

Metals processing: Special Metals, Tata Steel, …

Where to apply ?Technology Asset

criticality% totalequipment

Approach

Onlineprotection/CM/MCM

Highly criticalCritical

10-20% Full RCMCritical equipmentvalue add

MCM Midcriticality

30-40% Simple FMEASubmerged pumpsHazardous area

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Midcriticality

Simple FMEASubmerged pumpsHazardous area

Periodic datacollection

Low criticality 45-55% MaintenancetemplatesMCM for remotelocations.

Do nothing Not critical 5-10% Run to fail

Schematic diagram of an MCMinstallation

For each Motor,you need:

One MCM ofthe

appropriatetype

Three CurrentTransformersor Current

sensors of theappropriatesize / rating

For each group ofMCMs, you need:

A convertor –either RS485 -RS232 orRS485 – TCP/IP

For each siteinstallation youneed software –

MCM AES orbespoke (eg inWonderware,CM).

Slide 9

For each Motor,you need:

One MCM ofthe

appropriatetype

Three CurrentTransformersor Current

sensors of theappropriatesize / rating

For each group ofMCMs, you need:

A convertor –either RS485 -RS232 orRS485 – TCP/IP

For each siteinstallation youneed software –

MCM AES orbespoke (eg inWonderware,CM).

Installation andcommissioning

Typically installed in controlcabinets, simple process

Can also be fitted in separatecabinets for challengingapplications

Slide 10

Typically installed in controlcabinets, simple process

Can also be fitted in separatecabinets for challengingapplications

Automated learning MCM Enterprise Server detects

and sets up all devices

Each device then completes anautomated learning sequenceover about 10 days to establisha normal condition for theconnected equipment

Slide 11

MCM Enterprise Server detectsand sets up all devices

Each device then completes anautomated learning sequenceover about 10 days to establisha normal condition for theconnected equipment

Clustering Algorithm

Power Factor

C3

C4

During the learningperiod MCM treats eachoperating point of themotor as a cluster inthe three dimensionalspace (powerfactor,gain, supplyfrequency). Eachcluster has a separatemodel

In monitoring modeeach data is comparedwith the closest cluster

Motor OperatingCurve

MO

TOR

LO

AD

Slide 12

IPSConfidential

Frequency

C1C2

C4

During the learningperiod MCM treats eachoperating point of themotor as a cluster inthe three dimensionalspace (powerfactor,gain, supplyfrequency). Eachcluster has a separatemodel

In monitoring modeeach data is comparedwith the closest cluster

MO

TOR

LO

AD

MOTOR LOADGain (A/V)

Monitoring

3-PhaseMotor

3-PhaseMotor

Input

Comparison

AlarmLevelMeasured

OutputNORMAL

WATCH LINE

Slide 13

ComparisonComparison

EstimatedOutput

ModelModel

WATCHLOAD

EXAMINE 1

EXAMINE 2

Services

Service Description

Consulting RCM, commercial criticality analysis,effectiveness auditing, strategic roadmap,change management

Design Tech selection, installation plans,integration requirements

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Tech selection, installation plans,integration requirements

Implementation Project management, logistics, installation,commissioning, customization

Training Installation, operation, analysis, processchange

Analysis Diagnostics and prognostics, maintenanceadvice, engineering recommendations

Support Maintenance, upgrades, help desk

Electrical faultsFault type Causes Effects Impact

Supply distortion Bad supply orconditioning

Stator or rotoroverheating,vibration,efficiency

Energy cost

Voltage or currentunbalance

Failing windingsor capacitors,loose connections

Mechanicaldamage,efficiency,unneeded rewinds

Energy costs,rewinds

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Failing windingsor capacitors,loose connections

Mechanicaldamage,efficiency,unneeded rewinds

Insulationbreakdown

Thermal effects,contamination,moisture, wear

Shorts, majordamage

Secondarydamage, rebuilds

Rotor and statordamage

Excessivemovement, badrewind

Loss of power,severe damage,rebuilds

Process capability,rebuilds

Electric Power Research Institute:

47% of all motor faults, of which 10% rotors

Mechanical faults

Fault type Causes Effects Impact

Foundation orrotor looseness

Bad design,installation,deterioration

Distortion leadsto bearing andseal failures

Breakdowns orexcessive outage

Unbalance andmisalignment

Bad installation ormaintenance,fouling

Mechanicaldamage,efficiency loss

Breakdowns, upto 10% energycost

Bearings andtransmissionproblems

Bad installation,bad lubrication,wear

Progressivedamage,secondarydamage

Breakdowns,repair costs, lossof production

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Bearings andtransmissionproblems

Bad installation,bad lubrication,wear

Progressivedamage,secondarydamage

Breakdowns,repair costs, lossof production

Rotor damage Physical damage,corrosion

Loss of processefficiency, powerconsumption

Process capability,rebuilds, debrisdamage costs

Electric Power Research Institute:

53% of all motor faults

Operational faults

Fault type Causes Effects Impact

Cavitation inpumps

Bad design,incorrectoperation

High vibration,impeller damage

Breakdowns andreducedproduction

Flow turbulence infans, blowers

Bad design,incorrectmaintenance

Blade andductwork damage

Breakdowns andlost production

Slide 17

Filter and heatexchanger fouling

Debris build up Loss of processefficiency

Energy cost,maintenance cost

Lubricationproblems

Greasingschedules, badlubricationsystem, oil ageing

Loss of efficiency,progressivedamage tobearings, trans

Energy cost,breakdowns

Environmental faults

Fault type Causes Effects Impact

High energyconsumption

Electrical,mechanical,operational

Unnecessary cost High productioncosts, green taxes

Low efficiency Bad design,incorrectmaintenance

High energyconsumption,reduced output

High energy costs

Unbalance andmisalignment

Bad installation ormaintenance

Loss of efficiency Cost of energy for10% efficiencyloss

Slide 18

Unbalance andmisalignment

Bad installation ormaintenance

Loss of efficiency Cost of energy for10% efficiencyloss

Loose connections Bad installation ormaintenance

Supply heating 2-3% efficiencyloss

Case studies

Slide 19

Case 1: Seawater pump

Prediction of impeller failure between July 2009 and March 2010

Pump type had history of undetected failure (despite VA) resultingin expensive secondary damage

Impeller fault detected at an early stage and monitored in order todetermine latest safe time to maintain

During maintenance, fault was confirmed and repair was carried outinexpensively

Slide 20

Prediction of impeller failure between July 2009 and March 2010

Pump type had history of undetected failure (despite VA) resultingin expensive secondary damage

Impeller fault detected at an early stage and monitored in order todetermine latest safe time to maintain

During maintenance, fault was confirmed and repair was carried outinexpensively

Case 1: Spectrum changes

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Case 1: Trends

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Case 1: Power Factor

Slide 23

Case 1: Fault confirmation

Slide 24

Case study: Platform fan

Remote O&G platform, offcoast of Africa

HP Lift Gas CompressorDischarge Cooler Fan

Critical equipment, one of two

Production value around$3M/day

Risk value up to $1.5M/day

Slide 25

Remote O&G platform, offcoast of Africa

HP Lift Gas CompressorDischarge Cooler Fan

Critical equipment, one of two

Production value around$3M/day

Risk value up to $1.5M/day

5/4/13: Alarm

Slide 26

Alarm indicates high levels of misalignment, trend plot shows rapid deterioration.Maintenance intervention recommended.

15/4/13: Intervention

Slide 27

Equipment aligned and damaged shaft repaired. Trend shows that intervention hasBeen successful. Asset has returned to normal

15/4/13: Normal operation

Slide 28

Overview screen in iViewer shows that equipment has returned to normal.

7/5/13: Return of problem

Slide 29

A few days later, the misalignment response started to increase againindicating that the problem has returned.

Wear has also increased. This indicates that rubbing in thetransmission has caused local heating and thermal distortion leadingto misalignment.

Case 4: O&G platform fan

Remote O&G platform, off coast of Africa

HP Lift Gas Compressor Discharge Cooler Fan

Routine fault diagnosis and rectification

During normal remote monitoring detected increasingunbalance/misalignment and shaft wear

Fan stripped down for maintenance

Faults confirmed and rectified, effectiveness confirmed by continuedmonitoring

Traditional Preventative Maintenance program would have missedthe return of issue due to secondary damage, which may have ledto loss of asset.

Slide 30

Remote O&G platform, off coast of Africa

HP Lift Gas Compressor Discharge Cooler Fan

Routine fault diagnosis and rectification

During normal remote monitoring detected increasingunbalance/misalignment and shaft wear

Fan stripped down for maintenance

Faults confirmed and rectified, effectiveness confirmed by continuedmonitoring

Traditional Preventative Maintenance program would have missedthe return of issue due to secondary damage, which may have ledto loss of asset.

In Summary MCM supplies Equipment Health Monitoring (EHM) systems for

equipment driven by three-phase electric motors (more than 90%total equipment)

EHM allows maintenance costs to be reduced by as much as 90%,operating effectiveness increased by as much as 10%, andenergy efficiency to be increased by more than 10%

MCM delivers this potential by simplifying the process of systemselection, installation and commissioning

Enables expert to be located on the beach

MCM can be integrated with Avantis Condition Manager to provideautomated Work Request/Work Order generation.

Slide 31

MCM supplies Equipment Health Monitoring (EHM) systems forequipment driven by three-phase electric motors (more than 90%total equipment)

EHM allows maintenance costs to be reduced by as much as 90%,operating effectiveness increased by as much as 10%, andenergy efficiency to be increased by more than 10%

MCM delivers this potential by simplifying the process of systemselection, installation and commissioning

Enables expert to be located on the beach

MCM can be integrated with Avantis Condition Manager to provideautomated Work Request/Work Order generation.

Questions?

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