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AV-25 Rotating Equipment Health Machine Condition Monitoring-MCM Victor Lough Avantis social.invensys.com @InvensysOpsMgmt / #SoftwareRevolution /InvensysVideos Co-Authored By: Andy Bates Artesis /InvensysOpsMgmt /company/invensys Operations Management (not present for today s session) 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.
Why Progressive Operations? If you d had 3 months warning of 5 key failures over the past year, how much could you have saved? Loss of production Cost of spares Cost of labour Secondary damage Opportunity cost Slide 3
Achieving Design Life would be Nice Second generation 4 5 and th th 6th May 22nd and 23rd June 09 Examine 2 09 Moubrey recognition that 68% of 24th June 09 Examine 2 equipment is prone to fail early in its Examine 2 life. So called infant mortality. 23 April 17th April 09 th 09 This led to the popular bathtub curve Excessive invasion Unnecessary maintenance Incorrect Installation Incorrect commissioning Bad workmanship Poor Design Poor manufacturing Slide 4
Motor as Sensor Developing faults in the motor or in the equipment connected to it affect both the air gap and torsional dynamics between the motor stator and rotor These sensitive variations change the relationship between the motor input and the output signals that are then used to detect and diagnose faults System is able to use the motor as an effective sensor for the whole system, without the need for additional special sensors Slide 5
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
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
Where to apply? Technology Asset criticality % total equipment Approach Online protection/cm/ MCM Highly critical Critical 10-20% Full RCM MCM Mid criticality 30-40% Simple FMEA Periodic data collection Low criticality 45-55% Maintenance templates Do nothing Not critical Slide 8 Critical equipment value add Submerged pumps Hazardous area MCM for remote locations. 5-10% Run to fail
Schematic diagram of an MCM installation For each group of MCMs, you need: A convertor either RS485 RS232 or RS485 TCP/IP For each site installation you need software MCM AES or bespoke (eg in Wonderware, CM). Slide 9 For each Motor, you need: One MCM of the appropriate type Three Current Transformers or Current sensors of the appropriate size / rating
Installation and commissioning Typically installed in control cabinets, simple process Can also be fitted in separate cabinets for challenging applications Slide 10
Automated learning Slide 11 MCM Enterprise Server detects and sets up all devices Each device then completes an automated learning sequence over about 10 days to establish a normal condition for the connected equipment
Clustering Algorithm During the learning period MCM treats each operating point of the motor as a cluster in the three dimensional space (powerfactor, gain, supply frequency). Each cluster has a separate model In monitoring mode each data is compared with the closest cluster Slide 12 IPS Con Power Factor Motor Operating Curve C3 MOTOR LOAD C1 C2 MOTOR LOAD Frequency C4 Gain (A/V)
Monitoring Input 3-Phase Motor Measured Output Alarm Level NORMAL WATCH LINE Comparison WATCH LOAD EXAMINE 1 Model EXAMINE 2 Estimated Output Slide 13
Services Service Description Consulting RCM, commercial criticality analysis, effectiveness auditing, strategic roadmap, change management Design Tech selection, installation plans, integration requirements Implementation Project management, logistics, installation, commissioning, customization Training Installation, operation, analysis, process change Analysis Diagnostics and prognostics, maintenance advice, engineering recommendations Support Maintenance, upgrades, help desk Slide 14
Electrical faults Fault type Causes Effects Impact Supply distortion Bad supply or conditioning Stator or rotor overheating, vibration, efficiency Energy cost Voltage or current unbalance Failing windings or capacitors, loose connections Mechanical Energy costs, rewinds damage, efficiency, unneeded rewinds Insulation breakdown Thermal effects, contamination, moisture, wear Shorts, major damage Secondary damage, rebuilds Rotor and stator damage Excessive movement, bad rewind Loss of power, severe damage, rebuilds Process capability, rebuilds Electric Power Research Institute: 47% of all motor faults, of which 10% rotors Slide 15
Mechanical faults Fault type Causes Effects Impact Foundation or rotor looseness Bad design, installation, deterioration Distortion leads to bearing and seal failures Breakdowns or excessive outage Unbalance and misalignment Bad installation or maintenance, fouling Mechanical damage, efficiency loss Breakdowns, up to 10% energy cost Bearings and transmission problems Bad installation, bad lubrication, wear Progressive damage, secondary damage Breakdowns, repair costs, loss of production Rotor damage Physical damage, corrosion Loss of process efficiency, power consumption Process capability, rebuilds, debris damage costs Electric Power Research Institute: 53% of all motor faults Slide 16
Operational faults Fault type Causes Effects Impact Cavitation in pumps Bad design, incorrect operation High vibration, impeller damage Breakdowns and reduced production Blade and ductwork damage Breakdowns and lost production Flow turbulence in Bad design, fans, blowers incorrect maintenance Filter and heat exchanger fouling Debris build up Loss of process efficiency Energy cost, maintenance cost Lubrication problems Greasing schedules, bad lubrication system, oil ageing Loss of efficiency, progressive damage to bearings, trans Energy cost, breakdowns Slide 17
Environmental faults Fault type Causes Effects Impact High energy consumption Electrical, mechanical, operational Unnecessary cost High production costs, green taxes Low efficiency Bad design, incorrect maintenance High energy consumption, reduced output High energy costs Unbalance and misalignment Bad installation or maintenance Loss of efficiency Cost of energy for 10% efficiency loss Supply heating 2-3% efficiency loss Loose connections Bad installation or maintenance Slide 18
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) resulting in expensive secondary damage Impeller fault detected at an early stage and monitored in order to determine latest safe time to maintain During maintenance, fault was confirmed and repair was carried out inexpensively Slide 20
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, off coast of Africa HP Lift Gas Compressor Discharge Cooler Fan Critical equipment, one of two Production value around $3M/day Risk value up to $1.5M/day Slide 25
5/4/13: Alarm Alarm indicates high levels of misalignment, trend plot shows rapid deterioration. Maintenance intervention recommended. Slide 26
15/4/13: Intervention Equipment aligned and damaged shaft repaired. Trend shows that intervention has Been successful. Asset has returned to normal Slide 27
15/4/13: Normal operation Overview screen in iviewer shows that equipment has returned to normal. Slide 28
7/5/13: Return of problem A few days later, the misalignment response started to increase again indicating that the problem has returned. Wear has also increased. This indicates that rubbing in the transmission has caused local heating and thermal distortion leading to misalignment. Slide 29
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 increasing unbalance/misalignment and shaft wear Fan stripped down for maintenance Faults confirmed and rectified, effectiveness confirmed by continued monitoring Traditional Preventative Maintenance program would have missed the return of issue due to secondary damage, which may have led to loss of asset. Slide 30
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%, and energy efficiency to be increased by more than 10% MCM delivers this potential by simplifying the process of system selection, installation and commissioning Enables expert to be located on the beach MCM can be integrated with Avantis Condition Manager to provide automated Work Request/Work Order generation. Slide 31
Questions? Slide 32
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