CONDITION MONITORING

A K Darpe Department of Mechanical Engineering Indian Institute of Technology Delhi

Sound Maintenance Program: Need of the day

Periodic Measurements: Not foolproof Predictive Maintenance (online continuous monitoring): # catches the fault early # cost effective Narora Atomic Power Plant failure: could have been avoided FDAS, OLES-OSBUDD for KAPS developed

Sound Maintenance Program: Need of the day

Periodic Measurements: Not foolproof Predictive Maintenance (online continuous monitoring): # catches the fault early # cost effective Narora Atomic Power Plant failure: could have been avoided FDAS, OLES-OSBUDD for KAPS developed

Definition of Expert System

A computing system capable of representing and reasoning about some knowledge rich domain, which usually requires a human expert, with a view toward solving problems and/or giving advice. The level of performance makes it expert. Some also require it to be capable of explaining its reasoning. Does not have a psychological model of how the expert thinks, but a model of the experts model of the domain.

Expert System Developed in IIT Delhi

OLES (online expert system) OSBUDD (operator support and backup data

display). Uses knowledge base compiled by John S Sohre. Continuous online vibration and process data can be acquired from any machine. The diagnosis of the fault is almost instantaneous. The important vibration data be trended over any interval of time. Orbit plot, waterfall plot, can be plotted. An integrated signal analysis toolbox is provided.

DEVELOPMENT OF AN ONLINE DIAGNOSTIC SYSTEM FOR KAKRAPAR ATOMIC POWER PLANT

Schematic of the system

Frequency Domain Signal

TG Vibration Signals

Transducer

Signal
Conditioning

FDAS

Diagnostic System (OLES)

Process Signals

Signal Flow for FDAS

Signals received by FDAS

Vibration Signals
Bearing vibration signals - 12 Nos Shaft vibration signals - 8 Nos

Important Process Signals

Generator Power Condenser vacuum

Schematic of the system

OSBUDD
(Operator Support and Back Up Data Display) Displays processed data in various format Trend of important vibration parameters Expert system diagnostic results

Provision of reviewing past data

Demo and Help for operator assistance

Plots:

Time Domain Frequency Domain Trend Orbit Waterfall

Expert System Diagnosis Signal Processing Demo Help

Analysis:

Assistance:

Backup Data Loader

Expert System
Each fault produces a typical frequency pattern (signature) Sohres Database as knowledge base Direction and type (shaft/brg) of predominant vibration taken into account Expert system estimates probability of each fault, lists five most probable ones.

COMMERCIAL CONDITION MONITORING SYSTEMS Diagnostic tool from DSA International

Automated diagnostic system called Check-mate Uses frequency spectrum of vibration from common data collection systems (either offline or online) User can select from the list of vibration spectra available at any particular point of the machine of interest. After selection the expert system compares the vibration levels of that particular point with alarm levels and suitable remedial action can be taken In the latest version of check-mate up to 700 spectra can be automatically analyzed in under 10 minutes.

Check-Mate identifies
Unbalance. Off-set misalignment. Angular misalignment. Bent shaft. Looseness. Unequal foundation stiffness. Coupling lock-up. Bearing problems-preload, looseness, inner race, outer race, ball train defects. Gear defects-tooth wear, misalignment, eccentricity, broken or worn tooth/teeth, hunting tooth faults.
Cont

Check-Mate identifies
Sub-synchronous bearing instability. Electrical faults-cracked rotor bars, eccentric rotor. Rubs-rotor, axial. Belt problems. Cavitation. Oil whirl. Dry whirl. Check-mate identifies faulty readings caused by a loose or damaged sensor.

Unique Features of Check-Mate

Model based, object oriented and data driven . Machines are quickly modeled with in built parts such as gears, bearings, shafts and motors. Spectra are accessed simply by clicking on the measurement locations. Frequencies associated with the typical generic faults are easily displayed by clicking on that part's icon. Spectral peaks are quickly identified. The user can go the the part and ask for 1X, 2X, 3X rotation speed or the BPFO (outer race ball pass frequency) and multiples to be displayed on the current spectra.
Cont

Unique Features of Check-Mate

Trends for specific fault frequencies are extracted from waterfall diagrams. Trends will also accurately track harmonics and wide band frequencies. Alert levels are set for individual fault frequencies, harmonics and wide-band modulations. Actual frequencies for alerts are automatically recalculated for machine speed of each spectrum. Diagnostics include clear advice on appropriate operation or maintenance actions. DSA international can supply customized rules or machine parts to meet ones special requirements.

DSA International Corporation 4580 Marineview Crescent North Vancouver, BC V7R 3P5 Canada phone: 604-986-0936 fax: 604-986-0935 email: alees@dsaint.com

A Fault Diagnosis and Maintenance Expert System for Rotating Machinery

The FDMES for rotating machinery has its own distinguishing feature in both the rules and reasoning mode. Knowledge based rules of FDMES are compiled from diagnostic tables of mechanical faults. The FDMES can diagnose 58 kinds in 10 categories of mechanical faults give the second reasons: design and manufacture, installation and maintenance, operation and control, machine deterioration and give the methods of prevention and cure. FDMES is used in 18 large enterprises in China.

BENTLY NEVADA Data Manager

Bently Nevadas data manager (DM2000) with continuous, online data acquisition, archiving, and display capabilities. Static and dynamic data under steady-state and transient operating conditions can be collected. Data acquisition modes can be both automatically and manually initiated. Data display stations can be located where desired in LAN,WAN or RAS. MMS(Machinery Management Services) engineers are available for help. The MMS engineers may be able to determine the condition of machinery from the remotely transmitted data alone.

Display plots available

Current values, bar graph, machine train diagram, trend, fast trend, high resolution trend , multivariable trend, acceptance region, time base, shaft average centerline, spectrum/full spectrum, alarm list, system list, waterfall, bode, polar, cascade, plus orbit and plus spectrums. Along with expert system, Bently Nevada provides hardware and software products primarily designed for online acquisition and presentation of data and information. Bently Nevada provides portable condition monitoring solutions.

BENTLY NEVADA System 1TM

System 1 is a patented modular and scalable software platform for managing plant asset data and information. Increases asset availability and reliability by providing a single, integrated tool for storing, accessing, and managing plant production assets with information, rather than simply data. System 1 replaces previous Bently Nevada standalone online software programs such as Trendmaster 2000, data manager 2000, and machine condition manager 2000 by combining the functionality of these products into a single platform.
Cont

 Accepts data from any data source, not just Bently Nevada condition monitoring hardware. Provides tools to capture and use condition data, historical data, baseline data, nameplate data, asset properties, lessons learned, and other relevant information. Provides tools to link documents and files, write reports, and to exchange data with other systems. High-end data analysis tools for diagnostics and root cause analysis are also part of System 1 SYSTEM 1TM is designed to be modular and scalable.

Cont

 Using this platform, a solution can be built to support a wide range of user scenarios in many industries such as
Power generation Pipelines Refineries Marine Oil and gas Waste water treatment Food and pharmaceutical Semiconductor manufacturing Petrochemical Pulp and paper Metals and mining

MasCon/ ProCon
NAIDENS (an SKF group Company) MasCon/ ProCon online system monitors and diagnoses various process and machine component conditions, and provides automatic advice for correcting existing or impending conditions. MasCons in-built hardware auto-diagnosis system continuously checks all sensors, cabling and electronics for any faults, signal interruption, shortcuts, or power failure. Any malfunctions triggers an alarm, and in the case of system power failure the system will automatically restart when the power returns.
Cont

MasCon/ ProCon
Data is transferred via TCP/IP. It can be sent to company for quick help and action. 32 different sensors, signal and measurement configuration can be accommodated. Individual conditions for warning and alarm may be set for each point. By using expert guide, in-built software, One can add the new machines using simple mouse clicks. The frequency bands, resolution, defect frequencies, machine diagnosis are generated automatically. Damaged machine components are identified independently of the measurement point position.
Cont

 Warnings and alarms are indicated in machine picture by yellow or red color measurements. Measurements are made by mouse click over desired point with overdue measurement indicators. Remote access via modem or internet is available. Selected reference spectra may be fixed and automatically matched with new or earlier measurements. Early detection of bearing faults using DPE (digital peak enveloping). Triggering alarm levels may be set to adjust automatically to load level and rotational speed.
Cont

 Advanced turbine fault diagnostics system:

Detection of eccentricity change in coupling, Blade failure, Bearing instability, Steam whirl, Rotor crack, Rotor rubbing, Temporary rotor bow, Loose bearing pedestal, Inclined position of bearing, Electrical run-out, Mechanical run-out, Loose stator core in generator, Change of imbalance at shutdown, Radial bearing damage, Inter turn short circuit in generator rotor, etc.

Korea Institute of Science and Technology .

Development of integrated diagnostic system for rotating machinery. Development of a portable vibration monitoring system, which can transfer data on USB port. Diagnostic algorithm based on Sohres chart and a rule base. Monitoring test for various fault case by using integrated simulator. Tele-monitoring system by internet. Pre-step of new technology commercialization through a small-size and integration. Integrated machine health monitoring system.

CONDITION MONITORING
SENSORS Vibratory system Signal Acquisition

Knowledge base

Residual Life
Signal Processing Loading History

Fault Identification Damage Severity Identification Data Analysis And Representation

Gear Teeth Mesh Forces

Gear blank digs into pinion and withdraws once in one rotation Second gear teeth mesh

xcos(t)

xacos(at)

Time for 1 revolution of gear First gear teeth mesh Time for 1 revolution of gear Time (sec) Time (sec)

x(t ) [ x xa cos(a t )] cos t

First gear teeth mesh Time for 1 revolution of gear

Time (sec)

Amplitude Modulation in Gear Pair

x(t ) [ x] cost
With perfect gearing condition

modulation frequency i.e., rotational speed of the gear - a carrier frequencies i.e.,gear mesh frequency -

x(t ) [ x x a cos( a t )] cos t

With imperfect gearing condition

x(t ) [ x cost xa cost cos(at )] x cost

xa x cos( a )t a cos( a )t 2 2

Time domain information: mostly rich in content, little in information

User defined software for further processing Accelerometer

Charge I/P

Charge Amplifier

AID card Voltage

Vibration being sensed

Lab view software loaded on PC

Computer

VIBRATORY SYSTEM

ITEMS a) Charge based accelerometer (piezoelectric) b) ICP type Accelerometer c) Charge Amplifier (required only for charge type accelerometer) d) Analog to Digital Converter Card e) Labview Software for acquisition & subsequent signal processing.

COST IN RUPEES (Rs) 20,000 to 50,000 15,000 to 40,000 1,00,000 to 2,00,000 25,000 to 1,20,000 (depending upon number of channels & sampling rate) 80,000 onwards (basic version could cost more for pvt industry. 1,00,000 approx

f) MATLAB for making user defined

program

Lapto p

Charge Amplifier Portable data acquisition system Channel Tach s o

Acceleromet er Vibratory structure

ITEMS Portable Data Acquisition system (OROS, PULSE (B&K), Pimento with Virtual Lab (LMS), etc.

COST IN RUPEES (Rs) 18,00,000 roughly for 8 channel Data Acquisition System

Summary
Knowledge about the system Selection of transducers, acquisition system Features of signal processing and problems/issues associated with it Data representation techniques Interpretation Experience knowledgebase update