Presentation on theme: "2 Predictive Systems Engineering, Ltd Predictive Systems Engineering Diagnostics/Prognostics Predictive Maintenance Phase Angle/current analysis Vibration."— Presentation transcript:
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.
6 Predictive Systems Engineering, Ltd PAD failure signatures Loose motor foundations PAD failure signatures Loose motor foundations
7 Predictive Systems Engineering, Ltd PAD failure signatures Pre crystallizer.
8 Predictive Systems Engineering, Ltd PAD failure factor signatures Stirred reactor Failure Factor trend
9 Predictive Systems Engineering, Ltd Phase Angle Fractal
10 Predictive Systems Engineering, Ltd. 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. Phase Angle Fractal
11 Predictive Systems Engineering, Ltd Phase Angle Fractal The fractal in Figure 7 has an elliptical form. This form is associated with some initial abnormality in the bearing. Figure 7
12 Predictive Systems Engineering, Ltd Phase Angle Fractal 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
13 Predictive Systems Engineering, Ltd Phase Angle Fractal The disruption of the fan journal bearings was associated with growing fractal asymmetry. Figure 10
14 Predictive Systems Engineering, Ltd Phase Angle Fractal Figure 10 shows the trend of the fractal diameters ratio in the course of bearing disruption. Figure 10
17 Predictive Systems Engineering, Ltd Prognostics case story
18 Predictive Systems Engineering, Ltd iDiagnosticsWare functionality On Line Trend analysis
19 Predictive Systems Engineering, Ltd Machine Status Report iReporter
20 Predictive Systems Engineering, Ltd 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 System DCS – Distributed Control System SCADA - 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
21 Predictive Systems Engineering, Ltd 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 warnings OTHER CLIENT/ PSE INTERFACES Pi Historian and other archives CMMS, DCS, SCADA
22 Predictive Systems Engineering, Ltd. 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
23 Predictive Systems Engineering, Ltd 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
24 Predictive Systems Engineering, Ltd Diagnostics prognostics software
25 Predictive Systems Engineering, Ltd iReporter PredictiveOnLine employs an Intelligent User Interface presenting the results of the remote diagnostics & prognostics of the monitored objects. It includes; –animated icons symbolizing the status of a monitored object –the signatures and trends of key diagnostics indicators related to the detected abnormality, –the abnormality root cause, –the time remained to reaching a threshold, etc.
26 Predictive Systems Engineering, Ltd statistically analyzes the Diagnostics SoftwareiDiagnosticsWare 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 whenAfterwards, it builds a statistical model of the trend and forecasts when the trend reaches the thresholds related to ALERT or SEVERE conditions iDiagnosticsWare- performance analytics tool
27 Predictive Systems Engineering, Ltd Power Station Management Assistant Operation Schedule
28 Predictive Systems Engineering, Ltd Compressor protection Direct link to emergency shutdown PLC through RS485 bus or dry contacts
29 Predictive Systems Engineering, Ltd 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
30 Predictive Systems Engineering, Ltd Failures detected pumps Impeller imbalance Blocked impeller Cavitations Misalignment Bearing abnormalities, Loose foundation Resonance problem Sub-optimal operation and others..
31 Predictive Systems Engineering, Ltd Process Plant Equipment monitored Steam and Gas TurbinesBoilers Feed PumpsAir and gas compressorsElectrical motorsGeneratorsMillsCondensersHeat exchangersVacuum Pumps, etc.