Transcript Phase Angle Fractal

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
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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”.
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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.
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Phase Angle Machine Condition Assessment
instrumentation (eight machines installation)
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PAD failure signatures
Loose motor foundations
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PAD failure signatures
Pre crystallizer.
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PAD failure factor signatures
Stirred reactor Failure Factor trend
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Phase Angle Fractal
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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.
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Phase Angle Fractal
Figure 7
The fractal in Figure 7 has an elliptical form. This form is
associated with some initial abnormality in the bearing.
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Phase Angle Fractal
Figure 8
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.
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Phase Angle Fractal
Figure 10
The disruption of the fan journal bearings was associated with growing fractal
asymmetry.
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Phase Angle Fractal
Figure 10
Figure 10 shows the trend of the fractal diameters ratio in the course of bearing
disruption.
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iReporter
Diagnostics Prognostics Engineering Report
ereporter
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Prognostics case story
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iDiagnosticsWare functionality
On Line Trend analysis
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iReporter
Machine Status Report
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PSE - Predictive Maintenance - Technology Summary
THIS DEVICE WILL FAIL IN 8days ± 1 day!
CAN YOU BE THAT PRECISE?
PSE
Assets
Predictive
Maintenance
•Monitor rotating machinery; pumps ,
compressors, fans, gearboxes, mills, etc
•Scheduling and Planning made easy
and effective with PSE Predictive
Maintenance
CMMS – Computerised Management Maintenance System
DCS – Distributed Control System
SCADA - supervisory control and data acquisition
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•Integrate PSE with CMMS, SCADA,
DCS, Pi Historian etc
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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
CLOUD ACCESS
Diagnostics & prognostics
Monitoring reports
Remote expert
SMS and email warnings
 ePredictor – automated failure prediction report
OTHER CLIENT/ PSE INTERFACES
SENSOR NETWORK
Phase Angle, current and voltage sensors
Pi Historian and other archives
CMMS, DCS, SCADA
Smart wireless 3D accelerometers
Acoustic sensors
Zigbee and power line communication
Cell phone data connection modems
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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
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Predictive vs Preventive Maintenance
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
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Diagnostics prognostics software
• 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 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 equipment
• Prognosis of time when a tag or a Software Sensor value
reaches a threshhold value.
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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.
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iDiagnosticsWare- performance analytics tool
•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 “SEVERE”
conditions
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Operation Schedule
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Compressor protection
Direct link to emergency
shutdown PLC through RS485
bus or dry contacts
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Failures detected compressors
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Compressor valve flutter: spectral analysis of motor
current and phase angle.
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Compressor valve leakage: ultra sound probes installed on the
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cylinder heads.
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O-rings wear: thermodynamic analysis of temperatures before and after
cylinders.
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Shaft bearings malfunctions: ultra sound probes
Loose foundation: vibration analysis.
Rod wear: spectrum analysis of motor current & phase angle and vibration
analysis
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Short windings in electrical motors: Unbalance of motor current
VFD improper performance: spectral analysis of voltage SINEs in three
phases
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Rotor-stator gap problems: Phase Angle fractals
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Failures detected pumps
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Impeller imbalance
Blocked impeller
Cavitations
Misalignment
Bearing abnormalities,
Loose foundation
Resonance problem
Sub-optimal operation and others..
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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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