On-line Predictive Monitoring of Rotating Machinery
The Predictive Monitoring system continuously monitors and protects induction and synchronous motors and their driven rotating equipment. PSE “learns” the performance and health characteristics of the monitored equipment and provides;
PSE is much more than a monitoring system. It substantially prolongs the life cycle of the plant equipment and reduces the maintenance expenditures.
PSE applications
PSE can monitor a wide spectrum of rotating equipment:
- Pumps
- Fans
- Compressors
- Drives
- Chemical and petrochemical production equipment
- Mining equipment
- Food processing
- Industrial plants
- Power plants
System benefits
Based on a proprietary equipment PSE condition diagnostics technology utilizing diversified data acquisition and advanced signal processing revolutionizes Plant Asset Management by;
- advance warning of incipient failures, elimination of unexpected shut-downs;
- automated failure root cause evaluation and analysis,
- predicts time remaining to repair and time to failure,
- prediction of the residual life cycle of monitored machinery to support optimal planning of maintenance logistics
- shuts down the motor and driven equipment in emergency conditions (optional),
- detection of minor disturbances in health and performance of monitored equipment, which substantially reduces expenditures for corrective maintenance.
- audits electricity consumption.
- enables the Predictive Maintenance of equipment where the maintenance is performed only when it is really needed.
- PSE saves up to 20-30% of maintenance expenditures.
The early detection of equipment disturbances reduces the cost of corrective maintenance. This system allows a user to avoid unexpected outages, to schedule corrective maintenance in a planned manner and to reduce equipment downtime.
PSE tracks developing faults and provides alerts starting from early fault development then accelerated fault development to a prognostic of time remaining to failure.
PredictiveOnLine System
- It monitors operation of the induction motor and compares characteristics of the motor in operation with base line characteristics determined in advance.
- Variations of the motor’s characteristics from the known base line indicate an actual or approaching failure.
Predictive Parameters
PSE’s predictive function is based on our unique USA patent pending technology.
Rotating machine dysfunction caused by a disturbance or disturbances in the machine mechanism can be extremely complicated.
- A defective component influences the health of the others.
- The rates of growth of a disturbance into failure vary for different components.
- The rotating equipment failures are associated with numerous parameters. Most grow during the process of failure development, while others might reduce.
All of this makes the prognostics of machine residual life quite complex. To overcome these difficulties PSE has developed and successfully applied a unique technology, USA Patent pending, based on on-line aggregation of diagnostics parameters relating specific failures to a single “Failure Factor” (FF). The system tracks the changes of FF related to different failures and tracks which failure is most likely to cause ultimate failure and when the value of the FF associated with specific failure reaches its critical threshold values. The threshold values are evaluated by the system during baseline modeling of the machine performance.
Motor Failures Diagnosed:
- Uneven air gap between the rotor and stator
- Broken rotor bars
- Damage to the Stator Windings
- Insulation damage
- Motor Bearings failures
- Loose Foundation
- Motor Overload
- Current imbalance
- Voltage out of tolerance
VFD Drive Problems Identified:
- Power supply quality,
- Voltage imbalance,
Common Mechanical Equipment Problems Identified:
- Bearings (rolling)
- Bearings (thrust)
- Bearings (sleeve)
- Gears
- Out of balance
- Shaft Misalignment
- Loose Foundation
- Coupling wear
- Belt slippage
- Inefficient operation
- Damaged/impacted impeller
- Cavitation
- Eccentric impeller, blocked impeller
- Seal damage/leakage
Equipment Cloud Analyser (ECA) Concept for OEMs
ECA provides equipment manufacturers with a unique opportunity to build their own diagnostics & prognostics centre for after sales service of its products.
This service will provide an OEM with significant market advantages and will allow for extended product warrantees.
PSE is a sole supplier of a full set of hardware and software for supporting an OEM’s centre for remote monitoring of its products.
The OEM version of the Cloud Monitoring System with data acquisition instrumentation can be embedded into the OEM control equipment where data processing is performed at the OEM and/or PSE remote Diagnostics Prognostics Server.
Equipment Protection; ECA includes direct links to Equipment Programmable Logic Controllers or to local control networks. This configuration supports the emergency shut down of a piece of monitored equipment. Subject to system settings shut down can be effected with or without confirmation of the equipment operator.
PSE Data Acquisition measures/diagnoses :-
- RMS values of both current and voltage.
- Motor load.
- Misalignment or unbalance.
- Bearing failures
- Current and voltage unbalance.
- Stator core damage. vi.
- Stator inter-turn faults.
- Rotor bar health.
- Static and dynamic eccentricity.
- Real, reactive and apparent power
- Crest factor for both voltage and current.
- Harmonic distortion.
- Kurtosis Factor for Current and Phase Angle
- Total harmonic distortion for both voltage and current.
- Power factor
- Efficiency
- Volts/Hz ratio.
Electrical motors and VFD monitoring diagnostics instrumentation is located in Motor Control Centre, MCC, or in stand alone electrical cabinets.Monitoring Sensors will include the appropriate application of a selection of the following:
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Electrical voltage and current
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Vibration measurement instrumentation
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Temperature signal measurement instrumentation.
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Audio and Acoustic emission measurement instrumentation.
The proper differentiation of equipment faults requires knowledge of the characteristics of the processes that the monitoring equipment is applied to.Refineries, Petrochemical, Chemical, Oil & Gas industries operating in the explosive environment can use the PSE Intrinsic Safe Smart Sensors equipped with Power Line Communication modems or Intrinsic Safe RS485 networked sensors.
Mining Industry industry; communications via Fibre Optics Data Communication is available.
Underwater operating Smart Sensors have water proof enclosure and can operate with embedded Power Line Communication modems.
Each data acquisition instrument has its preferred application strength
- Phase Angle diagnostics is very sensitive with ability to detect minor disruptions in monitored equipment.
- Phase Angle/Current/Voltage Diagnostics is indispensable for diagnostics of equipment with difficult access, submersible equipment, cavity and canned pumps, etc. though some failures can not be diagnosed in the incipient phase of their development.
- Vibration diagnostics has good diagnostics capabilities but cannot always be applied.
- Audio and Acoustic Emission Smart sensors are very helpful for detecting incipient disruptions but for accurate differentiation of failure root causes and prognostics of equipment residual time to failure has to be combined with other sensors.
PSE comprehensive data acquisition system provides a customer with the best solution for cost effective monitoring of his equipment meeting customer’s budget and equipment performance requirements.
Installation and Service
PSE instrumentation hardware can be installed by a local technician. PSE/Martec provides remote hardware installation support, software installation and commissioning.
Remote administration and diagnostic service support of the monitoring system are provided under a surveillance contract by PSE/Martec.
Cloud Monitoring Platform
Cloud diagnostics platform incorporates:
- local networked diagnostics instrumentation and equipment controllers,
- Cloud Diagnostics & Prognostics software and databases located on the Cloud servers (PSE information Site)
- alert generation,
- upgrades to software and local server IT software.
The Cloud Monitoring Platform consists of:
- Wireless sensor network connecting the diagnostics sensors installed on equipment and in MCC’s with PLC controllers.
- Data acquisition software located on the customer site computer.
- Middleware software for data transfer to remote central server,
- eDiagnosticsWare – diagnostics, prognostics, protection software package, patent pending.
- eReporter- the software package supporting automated failure analysis and operation of an Internet site, for on line reports of performance and health of monitored equipment.
- Short status report with animated icons symbolizing the status of monitored equipment. The short report provides the maintenance team with the evaluation of time when the machine has to be stopped for corrective maintenance.
- Engineering report supplying the diagnostics of expected failures, diagnostics signatures and trends of main key indicators related to the failure.
- eMessenger – software package for automated eMail and SMS warnings of detected abnormalities.
- Multiple Location networking
- Import of other signal processing techniques
- Modernization of analog data acquisition systems
PSE is a modular system, which can be applied in appropriate configurations:
- The Cloud Monitoring system without the local diagnostics and prognostics server. The raw signals are wirelessly transferred from monitored equipment to the PSE Cloud server. The monitored reports are presented on the PSE Information Site and are accessible by authorized users. The warnings are sent by eMails ans SMS.
- The Cloud Monitoring System with data processing performed on the local diagnostics and prognostics Server incorporated into a LAN. The reports are produced on the PSE Cloud Server and are visible on the user work stations. The warnings are sent by eMails ans SMS.
- Portable Cloud Monitoring system targeted to prolonged inspections of customer equipment.
The Smart Wireless Current, Voltage, Phase Angle, Vibration and other sensors can be moved from one piece of equipment to another. In this application the data processing can be provided by a laptop connected to diagnostics & prognostics centre.
As opposed to manual vibration analysers PSE continuously retrieves the diagnostics information and can be remotely supported.