Monitoring & Diagnostic Center Technology: Transforming Equipment Reliability & Performance

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Leaders in ER Process & Technology Consulting

Bill WoyshnerBill.Woyshner@wscinc.biz610-909-3948

1. Equipment Reliability Program Deployment

2. M&D Center Development & Deployment Support

3. Continuous On-Line Monitoring (COLM) Technology Application

WSC Background

EPRI Monitoring & Diagnostics Center

TECHNICALSERVICES

NETWORKING• MAINTENANCE

• CONTROLS

• MONITORING

COMMUNICATIONS

PREDICTIVEMAINTENANCE

CONDITIONMONITORING

TECHNOLOGYTRANSFER

TRAINING

On-Line Monitoring Technology Project in 2011 // 30K+ Sensors in 50 Plants

DATA INFORMATION INSIGHT

Assets SensorsData Acquisition /

Plant ServersIntegration & Visualization

Monitoring & Diagnostics

10,000+ 33,000+2,400+ Nodes /

50+ Plant Servers11,000+ APR Models

Turbine Critical EquipmentSteam Turbine

Combustion TurbineGenerator

Boiler

Balance of PlantMotors, Pumps, Gearboxes,

FansTransformers

Iso-Phase Bus DuctsElectrical Buses

Phase I = Base InstallationTemperature

Accelerometers / VibrationTurbine Vibration Monitoring

(VDMS – Vibration Diagnostics Monitoring System)

ProximityOil Analysis

Phase II = Critical Asset SensorsCameras

Thermal CamerasInfrared Sensors (IR)

Electro Magnetic Signature Analysis (EMSA)

Motor Current Signature Analysis Sensors (MCSA)CT (foreign object & leak

detection)

Phase III = Performance SensorsGaps in performance

monitoring (combustion monitoring, etc.)

Operational SensorsFocuses on reducing

operational risk; event free index

NI CompactRIO(reconfigurable embedded

control and acquisition system)

NI cRIO-9068 / NI cRIO-9074

NI cRIO-9024 (Turbine)

HP ProLiant ServerML350p Gen8

NI InsightCM™ EnterpriseNI InsightCM™ Data Explorer

NI InsightCM™ Server

PlantView™Health Modules / Fleet-Wide

Dashboards

MS Power Business IntelligenceTBD

NI InSightCM™ Data ExplorerInStep PRiSM™

Pattern Recognition

Efficiency Monitoring& Thermal Modeling

Advanced AnalyticsTBD

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Equipment Reliability Process

• Time Based PM’s• Condition Monitoring

Tasks

Plant HealthMeetings

• CBM process• M&D Center/COLM• Equipment Inspections• System Health

CDM Tasks

(CMT’s) Condition Monitoring Tasks

Results Analysis & Corrective Action

Feedback for Improvement

• Establish MEL Critical Important Run-to-Repair

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Identify Criticality of each Plant Component

1Establish Optimum

PM Tasks 2

PM Implementation(Time Based &

CMT’s)3

Monitor System & Component Health 4

Daily & Outage Work Management Process

(Just-in Time)

Long Term Asset Management

• Risk Grids• Project Prioritization

6Monitor System & Component HealthCondition Based Maintenance Process

M&D Center• Apply APR – Early Detection of Equipment Anomalies• Apply Thermal Perf. Monitoring

Continuous On-Line Monitoring (COLM)• Low cost advanced sensors• Improve Early Detection of Equipment Anomalies

Condition Monitoring Technologies

MotorCurrent

Lube Oil

Thermography

Performance Monitoring

Vibration

Pressure

On-line Parameters

Component reliability/availability mgmt.Performing equipment assessmentsUpdate/management of component health status/reporting.1ST called when component health is questioned.Component maintenance task basis.(PM template)Continuous improvement of the maintenance task balance.

Component Ownership Attributes

CBM Process

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“Communication is Key”

Condition Based Maintenance Process

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Acquire Data

Derive Informati

on

Timely Corrective

Action

• Maintenance History• Operator Logs• Performance Testing• Off-line Inspections

• Vibration• IR Thermography• Oil Analysis• Electrical testing• NDE• Etc.

• Pressure• Temperature• Flow • Amps• Etc.

Data

Integration

Insights for

Decision Making

Equipment Condition Status Report

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Individual Component

Health Status

Equipment Assessment - on a periodic basis all the Collected (recent) Technology Exams are reviewed to form an overall assessment of the health of the equipment.

Technology Exam - equipment health information collected on a periodic basis via Manual or Automatic methods - such as Vibration, Lube Oil and Thermography, electrical testing, performance testing, etc..

Monitors process data available at the plants

Utilizes Advanced Pattern Recognition Software Applies New Smart Sensors

Applies Thermal Efficiency Monitoring Building dynamic models for major sites

M&D Center detects small changes

Notifies plant CBM specialist & system owners

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Typical M&D Center

• Fan Amps

• Motor Winding Temp

• Motor OB Bearing Temp

• Fan OB Bearing Temp

• Inlet Vane Position

• Ambient Temp

• Air Flow

Plot-0

4/6/2008 4:39:21.791 PM 4/9/2008 4:39 :21 .791 PM3.00 days

60

62

64

66

68

70

72

74

76

58

78

96

108

86

102

107

113

94

102

46

64

0

14

110

170

52

70

25

75

• Motor IB Bearing Temp

• Fan IB Bearing Temp

• Select related points

APR Model Development

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Advanced Pattern Recognition (APR)

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Monitoring with APR

Plot-0

4/6/2008 4:39:21.791 PM 4/9/2008 4:39 :21 .791 PM3.00 days

60

62

64

66

68

70

72

74

76

58

78

96

108

86

102

107

113

94

102

46

64

0

14

110

170

52

70

25

75

Control System Alarm Level

Equipment Condition Status Report – CBM Program Output

Individual Component

Health StatusAdvanced Pattern Recognition-New Condition Indicator

APR05/15/2011

05/15/2011

05/15/2011

05/15/2011

02/07/2011

05/15/2011

05/15/2011

05/15/2011

05/15/2011

05/15/2011

05/15/201105/15/2011

Technology Exam - equipment health information collected on a periodic basis via Manual or Automatic methods - such as Vibration, Lube Oil and Thermography, electrical testing, performance testing, etc..

Equipment Assessment - on a periodic basis all the Collected (recent) Technology Exams are reviewed to form an overall assessment of the health of the equipment.

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Traditional & Advanced Continuous On-Line Monitoring

Traditional COLM – Level 1: APR ApplicationUse existing/available sensors/process data to apply APR software/models to provide for monitoring & alerting –“Identifying Anomalies”

Traditional OLM – Level 1Apply APR Technology for Early Identification

of Equipment Anomalies

Advanced OLM – Level 2Dynamic Signal Feature Extraction, &

Advanced APR Models to Improve Anomaly Detection

Advanced OLM – Level 3Apply Multiple Algorithms & Expert

Systems for Auto Diagnosis

Advanced OLM – Level 4Apply Advanced Prognostic

Software Algorithms to Estimate Remaining Useful Life

Advanced COLM – Level 2: Additional SensorsUses FMEA analysis to influence addition of more online sensors. Dynamic signal feature extraction can improve “Anomaly Detection”. (Example: extract 1x, 2x features from a vibration sensor time waveform and APR models can be focused on identifying anomalies to allow for more effective diagnosis of equipment issues.

Advanced COLM – Level 3: Diagnostics Expands FMEA Analysis use to speed diagnosis. Greater application of advanced algorithm techniques and diagnosis support capabilities to validate anomalies and auto diagnose certain failures modes, based on sensor inputs.

Advanced COLM – Level 4: PrognosticsRequires both FMEA analysis and engineering studies on current condition and maintenance history to apply advanced algorithms to predict remaining useful life (RUL). Advanced applications also apply Artificial Intelligence (AI) and prescriptive technologies and provide recommended work packages associated with identified failure types

Value of Additional Sensors - Pump ExampleM&D Center (and COLM level I) Limitations

On-Line Monitoring Technology Project in 2011 // 30K+ Sensors in 50 Plants

DATA INFORMATION INSIGHT

Assets SensorsData Acquisition /

Plant ServersIntegration & Visualization Monitoring & Diagnostics

10,000+ 33,000+2,400+ Nodes /

50+ Plant Servers11,000+ APR Models

Turbine Critical EquipmentSteam Turbine

Combustion TurbineGenerator

Boiler

Balance of PlantMotors, Pumps, Gearboxes, Fans

TransformersIso-Phase Bus Ducts

Electrical Buses

Phase I = Base InstallationTemperature

Accelerometers / VibrationTurbine Vibration Monitoring

(VDMS – Vibration Diagnostics Monitoring System)

ProximityOil Analysis

Phase II = Critical Asset SensorsCameras

Thermal CamerasInfrared Sensors (IR)

Electro Magnetic Signature Analysis (EMSA)

Motor Current Signature Analysis Sensors (MCSA)

CT (foreign object & leak detection)

Phase III = Performance Sensors

Gaps in performance monitoring (combustion monitoring, etc.)

Operational SensorsFocuses on reducing operational

risk; event free index

NI CompactRIO(reconfigurable embedded control

and acquisition system)

NI cRIO-9068 / NI cRIO-9074

NI cRIO-9024 (Turbine)

HP ProLiant ServerML350p Gen8

NI InsightCM™ EnterpriseNI InsightCM™ Data Explorer

NI InsightCM™ Server

PlantView™Health Modules / Fleet-Wide

Dashboards

MS Power Business IntelligenceTBD

NI InSightCM™ Data ExplorerInStep PRiSM™

Pattern Recognition

Efficiency Monitoring& Thermal Modeling

Advanced AnalyticsTBD

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No M&D M&DCenters

maturedSmartGen

diagnostics

analysis

real time monitoring

manual data

Leveraging technology

Remain the same

Continuous On-line Monitoring TransformationNew sensors - integrated analysis – automated diagnostics & prognostics

Reduced 90% of all manual vibration data collection (60,000 points)

COLM Levels III and IVAdvanced Monitoring Diagnostics & Prognostics

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98%

Shaft Mis-alignment

>33%

Remaining Useful LifeRUL Indicators

<33%

63%

Motor DE Brg.

88%

Diffuser Mechanical

82%

Shaft Imbalance

82%

Motor Brg. Lubrication

Motor ODE Brg. Worn

24%

Motor DE Brg.

82%

Motor Overheat

74%

Power Supply Harmonics

92%

Power Cable damage

74%

Stator Winding Fault Rotor Bars Broken

30% 81%

Rotor Eccentric

96%

Pump Inboard Brg. Worn

96%

Loose Foundation

88%

Worn Internals

77%

Pump Cavitation

92%

Pump Otbrd. Brg. Worn

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ER Program – Return On Investment

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Questions?