model-based v-i systems: - using your existing electric motors to tell you about your driven...
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Model-based V-I systems: - using your existing electric motors to tell you about your driven equipment’s condition
Geoff Walker, Director, Artesis LLP
MEETA
The level 1 challenge• How to keep existing, sometimes
elderly, plant going at max performance and min cost, avoiding unexpected downtime
• Moving from BD to PM to CBM (PdM) is a frequently chosen route
Why Predictive?
Breakdown maintenancePlanned maintenance
50% breakdown maintenance
10% breakdown maintenance
Predictive maintenance
Cost
The level 2 challenge: getting to Predictive
• Adopting CBM / PdM is not easy:• Technology?• Cost?• Culture / resource pressures
Remember the level 1 challenge - How to keep existing, sometimes elderly, plant going at max performance and min cost, avoiding unexpected downtime
The level 2 solution: an easier way to get what you want
• NASA developed technology! – Model based V-I systems• Use your existing motor as a sensor• Just measure voltage and current (3-
phases)• Provides an astonishing amount of
information on your equipment• Electrical (insulation, rotor bars,
stator windings, supply)• Mechanical (eg imbalance /
misalignment / bearing problems)• Operational (eg cavitation,
blocked filters, even tidal effects!)
How does it work?
Install Learn Run
What it is, what it does, how it works
Voltage Input – shape / size
Volts in
Resulting current – shape / size
Current
Behaviour of system
1. Summary screen:
Which machines have a problem?
1. Summary screen:
Which machines have a problem?
2. Diagnostic screen:
What’s wrong with them?What do I have to do?
2. Diagnostic screen:
What’s wrong with them?What do I have to do?
3. Trend screen:
How long do I have to act?
3. Trend screen:
How long do I have to act?
4. Spectrum screen:
Analysis background
4. Spectrum screen:
Analysis background
Tech Case 1: typical example of MCM maintenance cost saving on water pumps – >90% less £
Series of pumps with history of catastrophic failure – needing complete replacement of pump and motor on each occasion
MCM detected developing deterioration and advised repair to pump (not detected by other techniques)
Pump was repaired at low cost (cold resin repair to casing, replacement of cheap wear rings)
Motor, shaft, bearings, impeller all re-used.Cost and disruption a fraction of previous
experience; a few hundred £ compared to several thousand £
Pumping Station
Fuel Pump
Misalignment
Fuel Pump
4th July; laser shaft alignment
4th July; laser shaft alignment
Trials of Shaft adjustmentsTrials of Shaft adjustments
3th July; Change of Oil Seal
3th July; Change of Oil Seal
Maintenance QA verification
Advantages of model-based V-I systems
No sensors on plant Easy to install Great for inaccessible equipment Not disturbed by maintenance activities
Easy to useEasy to understandCovers broad range of failure modes
Electrical, Mechanical and OperationalFits with cultureAllows adoption of CBM: No unplanned downtime
Conclusions
MCM allows you to do good things: improve performance, reduce costs, avoid unexpected downtime, improve efficiency.
It’s simple to install and simple to use
Try it!
If you want to know more…
Thankyou
GeoffWalker
Artesis LLP,
St John’s Innovation Centre
CowleyRoad, Cambridge CB4 0WS
GeoffWalker
Artesis LLP,
St John’s Innovation Centre
CowleyRoad, Cambridge CB4 0WS
T 0845 634 3854
M 07989 547411
E geoff.walker@arte
sis.com
GeoffWalker
Artesis LLP,
St John’s Innovation Centre
CowleyRoad, Cambridge CB4 0WS
GeoffWalker
Artesis, S
t John’s Innovation Centre
CowleyRoad, Cambridge CB4 0WS
T +44 (0) 845 634 3854
M +44 (0) 7989 547411
E geoff.walker@arte
sis.com