Presentation on theme: "PSE comprehensive system for on-line continuous"— Presentation transcript:
1PSE comprehensive system for on-line continuous monitoring of rotating machinery
2Predictive Systems Engineering Diagnostics/Prognostics Predictive MaintenancePhase Angle/current analysisVibrationAcousticMitigating risk of production interruptionsAutomating diagnosticsAutomating prognosticsAutomate detection of mechanical and electrical conditionCloud computingMulti-technology approachIntegrating diagnostics with CMMS and archive systemsZero unexpected equipment failures objectiveReduced operation losses and maintenance expenditures
3Phase Angle Diagnostics VoltageCurrentSmall 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”.PredictiveOnLine measures the gap or angle between the Voltage and Current curves. The fluctuations between these two curves are analysed to produce the Failure factors and Alerts.
4Phase Angle Machine Condition Assessment Mechanical disturbances in rotating equipment causes smallfluctuations in the moment on the shaft.The Phase angle of an AC electrical motor is proportional to themoment on the shaft.The analysis of the phase angle fluctuations allows PSE to detect andrecognize the mechanical disturbances in the rotating machinerydriven by the electrical motor.PSE has developed and patented a method for this diagnostics. Itsadvantage is that sensors (current transformer) are located in themotor electrical cabinet and not on the monitored machine itself.Phase Angle technology is valuable for machinery which is difficultto access, for low speed machinery, or for machinesoperating in harsh environments.The most important issue is the technology viability. The testingprovided by Mitsui Chemical, Japan, has shown that Phase AngleDiagnostics is much more sensitive than vibration analysis.This makes it valuable for all rotating equipment.
6PAD failure signatures Loose motor foundations This is an example of a loose foundation which affects all of the mechanical components of this fan.
7Pre crystallizer. PAD failure signatures This is an example of a loose foundation which affects all of the mechanical components of this fan.
8Stirred reactor Failure Factor trend PAD failure factor signaturesStirred reactor Failure Factor trendThis is an example of a loose foundation which affects all of the mechanical components of this fan.
9Phase Angle FractalFractal plots are one of many diagnostic tools utilized in the analysis of failure development.
10Phase 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.
11Phase Angle FractalFigure 7The fractal in Figure 7 has an elliptical form. This form is associated with some initial abnormality in the bearing.
12Phase Angle FractalFigure 8Figure 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.
13Phase Angle FractalFigure 10The disruption of the fan journal bearings was associated with growing fractal asymmetry.
14Phase Angle FractalFigure 10Figure 10 shows the trend of the fractal diameters ratio in the course of bearing disruption.
20THIS DEVICE WILL FAIL IN 8days ± 1 day! PSE - Predictive Maintenance - Technology SummaryTHIS DEVICE WILL FAIL IN 8days ± 1 day!CAN YOU BE THAT PRECISE?Predictive MaintenanceAssetsPSEMonitor rotating machinery; pumps , compressors, fans, gearboxes, mills, etcScheduling and Planning made easy and effective with PSE Predictive MaintenanceIntegrate PSE with CMMS, SCADA, DCS, Pi Historian etcCMMS – Computerised Management Maintenance SystemDCS – Distributed Control SystemSCADA - supervisory control and data acquisition
21PSE - Predictive Maintenance - Technology Summary PSE 's- CLOUD CONDITION MONITORING SOFTWAREiDiagnosticsWare – automates failure diagnosticsCloud Server Software:eReporter – user friendly web based alerts, reports, analysed dataeExpert – online access to remote expert assistanceePredictor – automated failure prediction reportSENSOR NETWORKPhase Angle, current and voltage sensorsSmart wireless 3D accelerometersAcoustic sensorsZigbee and power line communicationCell phone data connection modemsCLOUD ACCESSDiagnostics & prognosticsMonitoring reportsRemote expertSMS and warningsOTHER CLIENT/ PSE INTERFACESPi Historian and other archivesCMMS, DCS, SCADA
22Cost Benefit of PSE Cost Benefit Diagnostics - Chemical Plant Israel US$210,000 annual savings from extending their maintenance cycle from 12 to 14 monthsPayback time on initial cost of PSE – 1.1 monthsPSE currently monitors the reactor stirrerCost Benefit Prognostics - Power Plant NYOne day of downtime equals $600,000 revenue lossPayback time on initial cost of PSE preventing one day of downtime – 4.4 hours.PSE is currently monitoring critical pumps and compressors
23Predictive vs Preventive Maintenance Benefits of Predictive MaintenanceMaintenance 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
24Diagnostics prognostics software Principle Functionality:On line signal processing related to steady state and transitiveprocessesSystem customization by self-learning monitored machine / process behavior at baseline conditions.Aggregation of different tags into Software Diagnostics Sensors indicating the performance of specific electricity generation processes and/or machine failures.Automatic trend tracking and the early discovery of minor disturbances in the monitored processes and/or equipmentPrognosis of time when a tag or a Software Sensor value reaches a threshhold value.
25iReporter PredictiveOnLine employs an Intelligent User Interface presenting the results of the remote diagnostics & prognosticsof the monitored objects.It includes;animated icons symbolizing the status of a monitored objectthe signatures and trends of key diagnostics indicatorsrelated to the detected abnormality,the abnormality root cause,the time remained to reaching a threshold, etc.
26Disturbance Growth Prognostics: iDiagnosticsWare- performance analytics toolDisturbance Growth Prognostics:iDiagnosticsWare statistically analyzes the Diagnostics SoftwareSensor Trends and detects small changes related to machine health orprocess abnormalitiesAfterwards, it builds a statistical model of the trend and forecasts whenthe trend reaches the thresholds related to “ALERT” or “SEVERE”conditions
27Power Station Management Assistant Operation Schedule
28Direct link to emergency shutdown PLC through RS485 Compressor protectionDirect link to emergencyshutdown PLC through RS485bus or dry contacts
29Failures detected compressors Compressor valve flutter: spectral analysis of motorcurrent and phase angle.Compressor valve leakage: ultra sound probes installed on thecylinder heads.O-rings wear: thermodynamic analysis of temperatures before and after cylinders.Shaft bearings malfunctions: ultra sound probesLoose foundation: vibration analysis.Rod wear: spectrum analysis of motor current & phase angle and vibration analysisShort windings in electrical motors: Unbalance of motor currentVFD improper performance: spectral analysis of voltage SINEs in three phasesRotor-stator gap problems: Phase Angle fractals