1 predictiveonline predictive systems engineering vintec knowledge ltd
TRANSCRIPT
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PredictiveOnLine
PREDICTIVE SYSTEMS ENGINEERING
Vintec Knowledge Ltd.
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THE OPPORTUNITY
• Equipment maintenance consumes 7-14% of industrial production costs.– Industries cannot afford shutdowns.
– Unscheduled repairs are very expensive.
– Industries cannot afford having highly trained and educated staff on their maintenance payroll.
– Communication between academia and technicians is often lacking.
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THE PSE SOLUTION
Based upon early detection of incipient failures condition maintenance :
– Prevents breakdowns.
– Reduces repair expenditures.
– Reduces the volume of calendar maintenance.
NEW SERVICE PHILOSOPHY
• Corrective maintenance action needs to be done when needed, and not just to follow a schedule.
• Early detection of incipient failures provides savings in repair expenditures.
• Periodic maintenance according to the actual state of monitored equipment reduces the volume of periodic maintenance.
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PRODUCT CONCEPT
– Disruptions develop before malfunctions and not suddenly!
– Malfunctions are avoided by early detection of disruptions!
THE E-MAINTENANCE CONCEPT
Long Distance diagnostics,
our new motor current diagnostics,
Ultra-Sound emission analysis and other
diagnostic techniques will revolutionize
existing maintenance practices.
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BENEFITS
• Prevents Equipment Breakdowns.• Increases Equipment Availability.• Increases Equipment Life. • Decreases Maintenance
Expenditures.• Supports Less Skilled Human
Resources• Provides Diagnostics Information.
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Applications
• Turbines• Water Feed Pumps• Exhaust Fans• Compressors• Gears• Mills• Plant Air Compressors • Diesel and Electrical Generators• Ventilation Fans• Agitators• Cooling Towers• Electrical Motors
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Long Distance Diagnostics Service
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DIAGNOSTIC TECHNOLOGIESMain Technology:
Motor current signature analysisAdditional Technologies:• Ultra-Sound (Acoustic) Emission Analysis• Vibration analysis• Torsion analysis• Equipment Start Up and Shut Down and
other transient processes analysis• Robot proximity sensor signal processing
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Main components• Permanently installed sensors
• Distributed Predictive Units
• Plant Intranet Diagnostics server
• Operator consoles
• Plant executive work stations
• PSE Long Distance Diagnostics Support
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Sensors
• Motor Current and voltage Pick Ups• Two directional Accelerometers & Ultra-
Sound Emission Sensors• Torsion Vibration sensors• Phasors• We utilize the motor as a sensor to detect
motor torque fluctuations as indicators of mechanical disturbances in equipment
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Motor Current DPU Installation 8 Pieces of Monitored Equipment
Motor Control Center
Intranet
DPU
Current Pick Ups
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MONITORING TECHNOLOGY
• Diagnostics indicators definition.
• Base-line modeling.
• On line comparing of base line and current data.
• Automatic analysis of trends.
• Prediction of failures.
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Multi Modal Communication Capability (wireless, fiber optic,
power line, Bluetooth, hardwired)
DSP + PLC Modem
Sensors:
Communication Device:
Intranet
Power lines
DPUPLC Modem
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DISTRIBUTED PREDICTOR UNITS , DPU FUNCTIONS
– Data acquisition.
– Signal processing.
– Early detection of incipient disturbances
– Alarms generation.
– Alarms transactions by Control buses, Internet.
– Cable, Cellular, GSM communications.
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EMAINTWARE FUNCTIONALITY
• Automatic tracking of customer machinery conditions.
• Disturbance monitoring with evaluation of time to failure.
• Failure diagnostics.• Warning transaction.• Event history database.• Automatic upgrade of diagnostics knowledge
bases.
WHAT THE CUSTOMER SEES
A strong feature of the PSE system
provides the customer with clear and
simple warnings in the forms of
string messages and animated pictures.
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TREND ANALYSIS
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INTERNET IMPACT
Internet will revolutionize maintenance by:
• Remote automatic monitoring of machine health by direct access to local monitoring units.
• World-wide support by best diagnostics consultants.
• Two-way communication between maintenance team and Internet center.
• Just-in-time spare part management by B2B facilities.
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