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TRANSCRIPT
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
Slide 8
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
Slide 14
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
Slide 15
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
Slide 16
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
Slide 21
Case 1: Trends
Slide 22
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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