PSE comprehensive system for on-line continuous monitoring of rotating machinery

1. PSE comprehensive system for on-line continuous monitoring of rotating machinery

2. 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. Voltage Current Phase AngleDiagnostics 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. 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.

5. Phase Angle Machine Condition Assessmentinstrumentation (eight machines installation)

6. PAD failure signatures Loose motor foundations

7. PAD failure signatures Pre crystallizer.

8. PAD failure factor signatures Stirred reactor Failure Factor trend

9. Phase Angle Fractal

10. 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.

11. 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.

12. 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.

13. Phase Angle Fractal Figure 10 The disruption of the fan journal bearings was associated with growing fractal asymmetry.

14. Phase Angle Fractal Figure 10 Figure 10 shows the trend of the fractal diameters ratio in the course of bearing disruption.

15. Multi Disciplinary Signal Processing

16. Diagnostics Prognostics Engineering Report ereporter

18. On Line Trend analysis

19. Machine Status Report

20. THIS DEVICE WILL FAIL IN 8days ± 1 day! CAN YOU BE THAT PRECISE? • Monitor rotating machinery; pumps , compressors, fans, gearboxes, mills, etc • Scheduling and Planning made easy and effective with PSE Predictive Maintenance • IntegratePSE with CMMS, SCADA, DCS, Pi Historian etc CMMS – Computerised Management Maintenance System DCS – Distributed Control System SCADA - supervisory control and data acquisition

21. 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 email warnings • OTHER CLIENT/ PSE INTERFACES • Pi Historian and other archives • CMMS, DCS, SCADA

22. 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 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

24. Principle Functionality: 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 processesand/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.

25. 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. iDiagnosticsWare statistically analyzes the Diagnostics Software Sensor Trends and detects small changesrelated 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 Disturbance Growth Prognostics:

27. Operation Schedule

28. Direct link to emergency shutdown PLC through RS485 bus or dry contacts

29. 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. Impeller imbalance Blocked impeller Cavitations Misalignment Bearing abnormalities, Loose foundation Resonance problem Sub-optimal operation and others..