Resilience of Pumps and Pumping Systems Condition Monitoring and Energy Monitoring of your pumps in AMP7 / PR19 and the advantages of using MBVI (Model-Based Voltage and Current) Systems Geoff Walker Cambridge, UK
A few things from Ofwat about PR19: Ofwat 4 key themes: “improve day -today “Innovation must be at Government priorities and objectives: • Great Customer Service resilience by reducing the core of every • Long term resilience the number of supply • Affordable Bills (and greater efficiency) company to deliver • Protecting customers interuptions, sewer long-term resilience, • Resilience in the round • Making markets work flooding incidents and great customer service • Innovation pollution incidents” and affordability” “companies...need to “companies...need the “We expect “We expect make the best long- right information, companies to make companies to make term decisions about systems, processes, performance step changes in cost operations, governance and commitments” efficiency” maintenance and capabilities” investment” Source: Ofwat price review final Ofwat methodology – executive summary Dec 2017
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 only Three Generic Maintenance Strategies “If there is an effective and applicable Condition Based Maintenance approach possible, adopt it in preference to PM or BD” (RCM – MSG3) Condition Based / RCM VDM Predictive Maintenance (CBM / PdM) RCM Selection process Minimise Planned, Preventive Maintenance (PM) PM Order Order Breakdown Breakdown Breakdown Maintenance Maintenance Maintenance TPM TPM TPM (BD / RtF) Motivation & Chaos Organisation approach
Why predictive / Condition Based? Cost 50% breakdown maintenance 10% breakdown maintenance Predictive maintenance / CBM Planned maintenance Breakdown maintenance
Condition-Based Maintenance requires Condition Monitoring of some sort: The “P - F curve” traces Minor, repairable the deterioration of an pump damage, low individual asset Condition / cost to repair resistance to failure P otential Failure F unctional (first Failure detectable deterioration) Complete pump failure, secondary damage, high cost to P-F interval repair Time 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
Vibration Analysis currently represents around 85% of the CM technologies condition monitoring industry • Electrical test • Vibration analysis • Acoustic emission • Ultrasound • Lubrication analysis • Thermography • Motor current/electrical signature analysis • Model Based Voltage and Current (MBVI) analysis
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… Freevibrationanalysis.blogspot.com Velocimeter Prox Probe Drive Motor • • • Wound sensor Wound sensor – with large number of Magnet moving inside • coil Simultaneously creates precisely located windings • • and senses electrical Creates voltage and Stator windings simultaneously create signals and sense electrical signals current in windings • • • Voltage and current Transmits electrical and Magnet moving inside coil • magnetic fields over Transmits electrical and magnetic fields related to phenomena inside the machine small air gap over small air gap • Voltage and current related to Slide 9 phenomena inside the machine
Automatic identification of spectral peaks Typical outputs: Bar chart of condition showing each of: Overview of condition and automatic Automated advice depending on fault identified • Instantaneous condition 1. Maintenance Strategy Optimisation – provision of information on faults detected • Recent average condition • minimise costs, • Predicted condition - one month • minimise unplanned downtime and forecast • optimise capital expenditure (min Life Cycle costs) • Predicted condition – three month • via Condition Based Maintenance; forecast 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: 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 Slide 11
How do you get started - a low- cost, “toe in the water” using the P100 kit: 1. Get hold of an MBVI 2. Connect current and 3. Capture results and test kit – eg Faraday voltage sensors to create report – part Predictive Portable (think convenient points automated, part manual of it like a portable data collector) eg 1 - current clamps and voltage clips: Eg 2 – using existing test blocks: Slide 12
Recap and conclusions Pervasive Pump Condition Monitoring with MBVI systems addresses these: Ofwat Themes • Great Customer Service P Reduces unexpected downtime • Affordable Bills – a Step Change in Cost Efficiency P Optimised Energy Cost Optimised Maintenance Cost P • Resilience in the round – best long term decisions about operations, maintenance and investment…based on the right information, systems, processes, governance and capabilities P Information provided to wherever it is of benefit, 24x7, at LOW COST P • Innovation Absolutely!
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
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