GE BN AnomAlertGE-BN AnomAlert22 Case Studies

March 2011March 2011

Segment: Automotive Equipment:   Pump

Case 1

Company:    Automobile Manufacturer A Fault:              Stator Isolation Breakdown

Decreasing current unbalance level

2GE Title or job number

5/11/2011

Segment: Automotive Equipment:   Pump

Case 1

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Company:    Automobile Manufacturer A

q p p

Fault:              Stator Isolation Breakdown

AnomAlert gave alarm indicating aAnomAlert gave alarm indicating a developing electrical fault. Thermal camera results verified AnomAlert’s warnings. The pump motor was replaced.

Hot Spot on stator winding

3GE Title or job number

5/11/2011

Segment: Automotive Equipment:   Tower Fan

Case 2

Company:    Automobile Manufacturer A Fault:              Imbalance & Misalignment

AnomAlert first gave a warning of a problem on 16th October 2005, and diagnosed a looseness problem Thediagnosed a looseness problem. The decision was to wait for further indications.

Renewed alert on 19th November 2005 initiated an inspection and a loose

Increasing unbalance parameter level

initiated an inspection and a loose attachment bolt was found on 14thFebruary 2006.

Oct 16 2005

Oct 24 2005

Nov 19 2005

Feb 14 2006

4GE Title or job number

5/11/2011

Segment: Automotive Equipment:   Tower Fan

Case 2

Company:    Automobile Manufacturer A Fault:  Imbalance & Misalignment

Loose bolt 

Oct 05 Nov 05 Dec 05 Jan 06 Feb 06 Mar 06

Fixed foundation

correctly identified

Looseness indicated briefly, but then problem disappeared

Consistent alarm on foundations, imbalance and misalignment

Continued monitoring of foundation problem

Continued monitoring of imbalance and misalignment problem

Fixed foundation problem

5GE Title or job number

5/11/2011

Segment: Automotive Equipment:   Rubber Mixing Mill

Case 3

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Company:    Rubber & Tire Manufacturer

q p g

Fault:              Rotor Bar Crack

AnomAlert identified existing transmission and unbalance faultsand unbalance faults

Later, AnomAlert began giving “Rotor Fault” warning also

6GE Title or job number

5/11/2011

Segment: Automotive Equipment:   Rubber Mixing Mill

Case 3

Company:    Rubber & Tire Manufacturer Fault:              Rotor Bar Crack

The “Rotor Fault” trend showed development of the rotor fault

Vibration measurement also verified existence of broken rotor bars, confirming h A Al di ithe AnomAlert predictions

Increasing Trend

7GE Title or job number

5/11/2011

Segment: Oil & Gas Equipment:   Diesel Fuel Pump

Case 4

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Company:    Oil & Gas Company A

q p p

Fault:              Misalignment

This case shows that AnomAlert can be a very useful tool for quality

Diesel Fuel Pump

3th J l Ch f Oil3th J l Ch f Oil useful tool for quality assurance of maintenance work, showing whether alignment has been correctly

l f ll

Trials of Axle adjustmentsTrials of Axle adjustments

3th July; Change of Oil Felt

3th July; Change of Oil Felt

completed following a maintenance task.

4th July; axle adjustment done4th July; axle adjustment done

8GE Title or job number

5/11/2011

Segment: Aerospace Equipment:   Radar Antenna

Case 5

Company:    NATO Radar Base Fault:              Gear Box Defect

A gear box defect is d dFebruary 4

2003, the gear box changed

detected at a NATO radar base Early

January 24 2003, the problem starts

base. Early detection of this fault helped uninterrupted 

i foperation of the radar.

9GE Title or job number

5/11/2011

Segment: Water Equipment:   Pump

Case 6

Company:    Water Distribution Co. A Fault:              Loose Foundation & Unbalance

10GE Title or job number

5/11/2011

Segment: Water Equipment: Pump

Case 6

Segment: Water

Company:    Water Distribution Co. A

Equipment:   Pump

Fault:              Loose Foundation & Unbalance

Before Maintenance After Maintenance

February 19 2009

Before Maintenance After Maintenance

L April 29, 2008February 19, 2009Loose 

Foundation Problem

Before Maintenance After Maintenance

U b lApril 29, 2008

February 19, 2009

Unbalance Problem

11GE Title or job number

5/11/2011

Segment: Metals Equipment:   Reversing Cold Rolling Mill Fume Fan

Case 7

Company:    Iron & Steel Company AFume Fan

Fault:              Dirty Filter

12GE Title or job number

5/11/2011

Segment: Metals Equipment:   Reversing Cold Rolling Mill Fume Fan

Case 7

Company:    Iron & Steel Company AFume Fan

Fault:              Dirty Filter

This fan discharges dust‐laden air out of the factory via a filter. 

A Al t t t d t th b

Motor Current11.17.2008 04.15.2009

05.25.2009

AnomAlert started to warn the user by giving a “Watch Load” alarm on 15th April 2009. Motor Status 2 

Parameter

Examination of the motor current trend shows that the motor current had been 

ll th b

Watch Load Level

gradually decreasing since 17th November 2008. This indicates that the filter blockage started on that date and had been gradually deteriorating to the point wheregradually deteriorating to the point where it exceeded the AnomAlert alarm level on 15th April.

This drop off in current shows that the fan had not been extracting the desired volume of air, and hence the ventilation in the plant would be below design levels

13GE Title or job number

5/11/2011

the plant would be below design levels. 

Segment: Metals Equipment:   Reversing Cold Rolling Mill Fume Fan

Case 7

Company:    Iron & Steel Company AFume Fan

Fault:              Dirty FilterThe maintenance team attempted to clean th filt ith d i 25th A ilthe filter with compressed air on 25th April 2009, but it was not fully successful.  AnomAlert started giving a “Watch Load” alert again after just 1 month of operation.alert again after just 1 month of operation.

The team changed the filter completely on 20th August 2009. After this AnomAlert stopped giving alert signals and the motorstopped giving alert signals and the motor current reverted to its nominal value. 

M t C tMaintenance

Motor Current 08.20.2009

14GE Title or job number

5/11/2011

Segment: Food

C S R fi

Equipment:   Deep Well Pump

F lt C it ti

Case 8

Company:    Sugar Refinery Fault:              Cavitation

Just after AnomAlert’s LEARN period was completed, the AnomAlert warned b t f lt i f b dabout a fault in a frequency band associated with Cavitation.  

The maintenance team dismantled the pump and checked for cavitation Thepump and checked for cavitation. The photos show the damage of cavitation which can be observed as small pits on pump blade, hence confirming the diagnosisdiagnosis.

Increasing failure level

15GE Title or job number

5/11/2011

• After maintenance, AnomAlert stopped warning.

Segment: Automotive Equipment:   Exhaust Fan

Case 9

g

Company:    Automobile Manufacturer B

q p

Fault:              Belt Looseness

AnomAlert indicated a transmission fault, ,so the engineers looked at the trending data, which pointed to a loose belt. 

Increasing failure l l

The maintenance team confirmed belt looseness. 

level

Belt tension starts to loose

Belt looseness would tend to result in slippage, which in turn would mean that the motor could not transmit all the power to the fan.  This was consistent with the decrease in the three phase currents. 

Decreasing  current level

16GE Title or job number

5/11/2011

Segment: Power Generation Equipment:   Feed Water Pump

Case 10

Company:    Power Generation Company A Fault:              Bearing Fault

One month after the AnomAlert installation, AnomAlert indicated a developing “Bearing” fault. Maintenance team verified the bearing f lt d l d th b i f th

Developing bearing  failure 

fault and replaced the bearing of the motor. After the maintenance action AnomAlert stopped giving alarm verifying the effectiveness of the

03.26.2009 03.30.2009

verifying the effectiveness of the maintenance action.

03 30 2009

AnomAlert Alarm history Examine 1 Level

03.26.2009 03.30.2009

17GE Title or job number

5/11/2011

Segment: Water Equipment:   Pump

Case 11

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Company:    Saline Water Conversion

q p p

Fault:              Stator Failure

The frequency spectrum indicates stator i di bl i b th t 120 Hwinding problem in both pumps at 120 Hz 

as shown in the figure below. 

Both pumps are stopped and then d h d

Current Balance

restarted in the same day on May 14, 2007. AnomAlert long term trending data shows an increase in current balance parameters and amplitude variations in

May 14, 2007

parameters and amplitude variations in currents before and after May 14, 2007.

S and T phase currents before S apped S and Tcurrents before May 14, 2007

Swapped S and T phase currents

18GE Title or job number

5/11/2011

Segment: Manufacturing Equipment:   Compressor

Case 13

g g

Company:    Battery Manufacturer

q p p

Fault:              Bearing Fault

l dAnomAlert started giving intermittent warnings on September 2005, and a bearing problem was diagnosed by AnomAlert Deterioration was kept underAnomAlert. Deterioration was kept under review until January 2006. When carried out, maintenance and repair actions verified the diagnostic assessment of AnomAlert.

On later examination of the AnomAlert trends, it was found that the bearing problem was detected even earlier that 13th September2005, but the severity was not sufficient to give rise to an alert. This demonstrates the capability of AnomAlertdemonstrates the capability of AnomAlert to indicate developing faults at a very early stage.

19GE Title or job number

5/11/2011

Segment: Manufacturing Equipment:   Compressor

Case 13

Company:    Battery Manufacturer Fault:              Bearing Fault

Aug 05 Sept 05 Oct 05 Nov 05 Dec 05 Jan 06

No problem, Progress of b i bl

Problem fixed, having had 3

other than minor supply issue

Bearing problem indicated, with 3 month warning

bearing problem monitored –early indication in August

months to prepare

20GE Title or job number

5/11/2011

g in August

Segment: Metals Equipment:   Pump

Case 14

Company:    Iron & Steel Company B Fault:              Coupling

Coupling fault d d ddetected and remedied.

21GE Title or job number

5/11/2011

Segment: Manufacturing Equipment: Phosphate Pump

Case 15

Segment: Manufacturing

Company:    Home Appliance Man.

Equipment:   Phosphate Pump

Fault:              Bearing Defect & Bent Shaft

Bearing faultChange of bearings and shaft

Change of bearings and shaft

Change of Change of Increase in the 10thIncrease in the 10th

Bearing fault detected. The same fault indication repeated againg

bearingsg

bearingsthe 10th and  12th mechanical parameters. 

the 10th and  12th mechanical parameters. 

repeated again later. Further analysis indicated t b t h ftto an bent shaft which was causing the fault.

22GE Title or job number

5/11/2011

Segment: Automotive Equipment:   Pump

Case 16

Company:    Automobile Manufacturer C Fault:              Unbalance

AnomAlert started giving ‘Unbalance’ i d ft it bwarning and soon after it became 

nearly consistent, on 28 th May 2010.

Maintenance team checked the motor d f d h b land verified the imbalance.

23GE Title or job number

5/11/2011

Segment: Automotive Equipment:   Pump

Case 16

Company:    Automobile Manufacturer C Fault:              Unbalance

Increasing 

‘Unbalance’ and ‘Motor Status 2’ parameters show the development of the

failure trend

parameters show the development of the fault.

05.28.2010

Motor Status 

24GE Title or job number

5/11/2011

Segment: Pharmaceutical Equipment:   Ventilation Fan

Case 17

g

Company: Pharmaceutical Manufacturer

q p

Fault:              Turbulence

Discontinuous but frequent warnings regarding ‘Driven Equipment Fault’ were detected on a Ventilation Fan, that had been monitored by AnomAlert.

After a detailed investigation, it was realized that the warning was being given g g gwhile the monitored fan was running together with the other fan supplying air to the same ventilation duct.

It was observed that when two motors run together they will cause turbulence in air flow. 

25GE Title or job number

5/11/2011

Case 18

Segment: Oil & Gas Equipment: Reciprocating CompressorSegment: Oil & Gas

Company:    Oil & Gas Company B

Equipment: Reciprocating Compressor

Fault:  Valve Leaking

Baseline from June 2010 showingclear, valve related sideband energy

LNG compressors were being monitored by VA,which was not detecting problems. AnomAlertwas then fitted to the compressors. Weanalyzed the results and advised that therewere leaking valves that should be attended toat the next overhaul. When the equipmentwas stripped down, the diagnosis wasconfirmed. Following the overhaul, theAnomAlert was put back into learn mode toi PSD hi h h d i ifi l

October 2010 

give a new PSD curve, which had a significantlydifferent shape from the earlier one,confirming that we detected the changeres ltin from the o erha l Vibration Anal sisresulting from the overhaul. Vibration Analysisdetected no change whatsoever.

26GE Title or job number

5/11/2011

Baseline from October 2010 following an overhaul. It can be seen that the valve sidebands are no longer present but there is broadband noise from one of the piston baffles.

Case 19

Segment: Oil & Gas Equipment:   LNG Pump

AnomAlert correctly identified that the

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Company:    Oil & Gas Company C

q p p

Fault:              Shaft Deflection

AnomAlert correctly identified that the pump had no major faults

No major faults –all green

27GE Title or job number

5/11/2011

Case 19

Segment: Oil & Gas Equipment: LNG PumpSegment: Oil & Gas

Company:    Oil & Gas Company C

Equipment:   LNG Pump

Fault:              Shaft Deflection

AnomAlert trends revealed that the pump was experiencing increased rub energy when the load was too high

The cause of this was slight movement in one of the shaft bearings causing wear toone of the shaft bearings causing wear to the shaft and shaft deflection.

This was confirmed during strip down work on the pump and was related to a design problem that has since been eliminated.

28GE Title or job number

5/11/2011

Segment: Water Equipment: Pump

Case 20

AnomAlert began giving load alarms in

Segment: Water

Company:    Water Distribution Co. B

Equipment:   Pump

Fault:              Pump Blockage

AnomAlert began giving load alarms in September 2010.

Some inherent friction‐related faults were identified in the frequency spectrumidentified in the frequency spectrum.

29GE Title or job number

5/11/2011

Case 20

Segment: Water Equipment: Pump

AnomAlert began giving load alarms in 

Segment: Water

Company:    Water Distribution Co. B

Equipment:   Pump

Fault:              Pump Blockage

September 2010 and the active power of the pump dropped drastically in December.

The cause was a piece of wood blocking thepump inlet.

30GE Title or job number

5/11/2011

Case 21

Power from waste generation station.

Segment: Power Generation

Company:    Power Generation Company B

Equipment:   ID Fan

Fault:              Fouling

Between shutdowns the ID Fan system f l l di t d d ffi ifouls leading to reduced efficiency.

AnomAlert identifies this point byAnomAlert identifies this point by recognising the difference in the load conditions of the motor.

31GE Title or job number

5/11/2011Load alarm as power drops off / increases!

Case 21

Segment: Power Generation Equipment: ID Fan

The trends highlight the gradual change in  Temporary, short term, changes in power 

Segment: Power Generation

Company:    Power Generation Company B

Equipment:   ID Fan

Fault:              Fouling

current between shutdowns, indicating that the system is fouling and that the fan is working harder to overcome this.

can also be seen to have a large effect on the vibration response of the machine.

32GE Title or job number

5/11/2011

Segment: Oil & Gas Equipment: Pump

Case 22

Segment: Oil & Gas

Company:Oil & Gas Company D

Equipment:   Pump

Fault:              Stator Insulation Progression

Frequent alarm and trend responses indicated changes in internal motor conditions.

Green yellow andGreen, yellow and blue lines correspond to internal electrical faultfault

33GE Title or job number

5/11/2011

Case 22

Segment: Oil & Gas Equipment: Pump

The trending showed that there was 

Segment: Oil & Gas

Company:  Oil & Gas Company DEquipment:   Pump

Fault:              Stator Insulation Progression

significant phase current in addition to the stator‐related trend increases and alarms.

Red line (Ir) and yellow line (Is)

Currents in the three phases vary in shape and separation

Red line (Ir) and yellow line (Is) cross over frequently, indicating inconsistent behaviour between the phases

34GE Title or job number

5/11/2011