of your pumps in AMP7 / PR19 and the advantages of using MBVI - - PowerPoint PPT Presentation

Condition Monitoring and Energy Monitoring

• f your pumps in AMP7 / PR19

and the advantages of using MBVI (Model-Based Voltage and Current) Systems

Geoff Walker Cambridge, UK

Resilience of Pumps and Pumping Systems

Ofwat 4 key themes:

• Great Customer Service
• Affordable Bills (and greater efficiency)
• Resilience in the round
• Innovation

“companies...need the right information, systems, processes, governance and capabilities”

A few things from Ofwat about PR19:

Source: Ofwat price review final methodology – executive summary Dec 2017

Government priorities and objectives:

• Long term resilience
• Protecting customers
• Making markets work

“We expect companies to make performance commitments” “improve day-today resilience by reducing the number of supply interuptions, sewer flooding incidents and pollution incidents”

Ofwat

“Innovation must be at the core of every company to deliver long-term resilience, great customer service and affordability” “We expect companies to make step changes in cost efficiency” “companies...need to make the best long- term decisions about

• perations,

maintenance and investment”

Smarter Pump Operation, Monitoring and Maintenance has a BIG ROLE to play

• 1. Maintenance Strategy Optimisation –
• minimise costs,
• minimise unplanned downtime and
• optimise capital expenditure (min Life Cycle costs)
• via Condition Based Maintenance;
• 2. Energy optimisation –
• pump-by-pump energy consumption
• identify energy saving opportunities
• provide cost-justified corrective actions;
• 3. The right information, systems, processes, governance and capabilities
• Operation optimisation
• Pervasive communication
• Internet of things / Industry 4.0

Maintenance Strategy Optimisation – there are

• nly Three Generic Maintenance Strategies

Breakdown Maintenance Breakdown Maintenance Breakdown Maintenance (BD / RtF) Chaos PM Order Planned, Preventive Maintenance (PM) Order Minimise RCM Condition Based / Predictive Maintenance (CBM / PdM) VDM RCM Selection process TPM Motivation & Organisation approach TPM TPM

“If there is an effective and applicable Condition Based Maintenance approach possible, adopt it in preference to PM or BD” (RCM – MSG3)

Why predictive / Condition Based?

Breakdown maintenance Planned maintenance 50% breakdown maintenance 10% breakdown maintenance Predictive maintenance / CBM Cost

Condition-Based Maintenance requires Condition Monitoring of some sort:

The “P-F curve” traces the deterioration of an individual asset

Minor, repairable pump damage, low cost to repair Complete pump failure, secondary damage, high cost to repair

Condition / resistance to failure Potential Failure

(first detectable deterioration)

Functional Failure Time P-F interval

May already have had 98% of fault-free life by this point

Running to complete failure can result in much higher costs than intervening when fault first detected

CM technologies

• Electrical test
• Vibration analysis
• Acoustic emission
• Ultrasound
• Lubrication analysis
• Thermography
• Motor current/electrical signature analysis
• Model Based Voltage and Current (MBVI) analysis

Vibration Analysis currently represents around 85% of the condition monitoring industry

Vibration Monitoring has been the most widely used CM technique but it has some limitations

VA works, but can struggle with:

• Inaccessible / Submerged / Remote equipment?
• Equipment in Hazardous Environments?
• Equipment operating at varying speeds (eg inverter driven)?
• Equipment operating at varying loads (eg inverter driven)?
• Equipment subject to electrically generated signals (eg inverter

driven)?

• Equipment displaying torsional vibration phenomena?
• Most electrical problems?

And VA hardware issues:

• Need for (re-)calibration of sensors
• Vulnerability of sensors to mechanical damage
• Installation costs of long cable runs
• Multiple sensors adds to cost

Slide 8

The drive motor can be thought of as a vibration sensor with many similarities to familiar prox probes and velocimeters…

Slide 9

Freevibrationanalysis.blogspot.com

Prox Probe

• Wound sensor
• Simultaneously creates

and senses electrical signals

• Transmits electrical and

magnetic fields over small air gap Velocimeter

• Magnet moving inside

coil

• Creates voltage and

current in windings

• Voltage and current

related to phenomena inside the machine Drive Motor

• Wound sensor – with large number of

precisely located windings

• Stator windings simultaneously create

and sense electrical signals

• Magnet moving inside coil
• Transmits electrical and magnetic fields
• ver small air gap
• Voltage and current related to

phenomena inside the machine

Typical outputs:

Overview of condition and automatic provision of information on faults detected

Bar chart of condition showing each of:

• Instantaneous condition
• Recent average condition
• Predicted condition - one month

forecast

• Predicted condition – three month

forecast

Automatic identification of spectral peaks Automated advice depending on fault identified

• 1. Maintenance Strategy Optimisation –
• minimise costs,
• minimise unplanned downtime and
• optimise capital expenditure (min Life Cycle costs)
• via Condition Based Maintenance;
• 2. Energy optimisation –
• pump-by-pump energy consumption
• identify energy saving opportunities
• provide cost-justified corrective actions;
• 3. The right information, systems, processes, governance and capabilities
• Operation optimisation
• Pervasive communication
• Internet of things / Industry 4.0

MBVI systems (ie using the motor as a sensor) see similar phenomena to accelerometers:

Slide 11

The motor outputs are generally MORE sensitive to torsional signals and LESS sensitive to radial signals than conventional accelerometers. They are surprisingly sensitive to both journal bearing phenomena and REB phenomena. And of course also provide info on electrical phenomena

• 1. Get hold of an MBVI

test kit – eg Faraday Predictive Portable (think

• f it like a portable data

collector)

How do you get started

• a low-cost, “toe in the water” using the P100 kit:

Slide 12

• 2. Connect current and

voltage sensors to convenient points eg 1 - current clamps and voltage clips: Eg 2 – using existing test blocks:

• 3. Capture results and

create report – part automated, part manual

Recap and conclusions

Ofwat Themes

• Great Customer Service
• Affordable Bills – a Step Change in Cost Efficiency
• Resilience in the round – best long term decisions about operations,

maintenance and investment…based on the right information, systems, processes, governance and capabilities

• Innovation

Pervasive Pump Condition Monitoring with MBVI systems addresses these: Reduces unexpected downtime

P

Optimised Maintenance Cost

POptimised Energy Cost P

Information provided to wherever it is of benefit, 24x7, at LOW COST

P

Absolutely!

P

Conclusions

• MBVI systems can address most of the problems that have

blocked widespread adoption of CBM strategy

• The underlying techniques are familiar to VA practitioners –

sensing to turn mechanical signals into electrical signals, then spectral analysis to identify faults and severity

• It can be used on otherwise tricky assets
• It can give you new insights (rubbing, turbulence, corrosion,

journal bearings) that can be harder to see via VA

• You can start simply with a portable test kit, just like with a

portable vibration data collector, and move to permanent installation once you have satisfied your own proof-of-concept

• It’s not scary as long as you dare speak to an electrical

engineer!

• Give it a go! – if you are interested, just talk to me afterwards.

Slide 14

Feedback and Questions

• And if you want to know more, just give me a call or search MBVI
• Geoff.walker@faradaypredictive.com

Slide 1